Maintenance Manual: Equipped With The Ge Fanuc 18T Dual Path Control

MAINTENANCE MANUAL
TP1960A
CONQUEST® ST216, ST220 and ST225

Swiss-Turn CNC Lathes
Equipped with the
GE FANUC 18T DUAL PATH CONTROL
Manual No. M-318A Litho in U.S.A.

Part No. M A-0009500-0318 June, 1998
- NOTICE -
Damage resulting from misuse, negligence, or accident is not covered by the
Hardinge Machine Warranty.
Information in this manual is subject to change without notice.

This manual covers the maintenance of the Hardinge CONQUEST®
ST-216, ST-220 and ST-225 Swiss-Turn CNC Lathes equipped with the
GE Fanuc 18T Dual Path control.
In no event will Hardinge Inc. be responsible for indirect or consequential
damage resulting from the use or application of the information in this
manual.
Reproduction of this manual in whole or in part, without written permis-
sion of Hardinge Inc., is prohibited.
CONVENTIONS USED IN THIS MANUAL

- WARNINGS -
Warnings must be followed carefully to avoid the possibility of personal in-
jury or damage to the machine, tooling, or workpiece.
- CAUTIONS -
Cautions must be followed carefully to avoid the possibility of damage to the
machine, tooling, or workpiece.
- NOTES -
Notes contain supplemental information.
Hardinge Inc.
One Hardinge Drive
P.O. Box 1507
Elmira, New York 14902-1507 USA
www.hardinge.com
1998, Hardinge Inc. M-318A

READ ALL OF THESE INSTRUCTIONS CAREFULLY BEFORE STARTING
MAINTENANCE OR REPAIR ON THE SWISS-TURN CNC LATHE.
The technicians who use this manual should have a general knowledge of machine maintenance
and repair. This general knowledge coupled with the following manual will greatly reduce or eliminate
downtime of this machine.
When machine maintenance is performed by persons not familiar with the operation of this equip-
ment, the Operator’s Manual (M-317) must be consulted when instructions require that the machine
be run.
- WARNING -
Occupational Safety and Health Administration (OSHA) Hazard Communica-
tion Standard 1910.1200, effective September 23, 1987, and various state
“employee right-to-know laws” require that information regarding chemicals
used with this equipment be supplied to you. A complete list of the chemi-
cals used with this machine, their reference data sheet numbers, and their
suppliers appears as an insertion at the end of this manual. Refer to the ap-
plicable section of the Material Safety Data Sheets supplied with your ma-
chine when handling, storing, or disposing of chemicals.
Machine should only be used with a bar feed approved by Hardinge Inc.
HARDINGE SAFETY RECOMMENDATIONS

Your Hardinge machine is designed and built for maximum ease and safety of operation. However,
some previously accepted shop practices may not reflect current safety regulations and procedures,
and should be re-examined to insure compliance with the current safety and health standards.
Hardinge Inc. recommends that all shop supervisors, maintenance personnel, and machine tool
operators be advised of the importance of safe maintenance, setup, and operation of Hardinge-built
equipment. Our recommendations are described below. READ THESE SAFETY RECOMMENDA-
TIONS BEFORE PROCEEDING ANY FURTHER.
READ THE APPROPRIATE MANUAL OR INSTRUCTIONS before attempting operation,

programming, or maintenance of the machine. Make certain that you understand all in-
structions.
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 per-
formed and the equipment is known to be in good working order.
WARNING or INSTRUCTION TAGS are mounted on the machine for your safety and in-
formation. Do not remove them.
DON’T ALTER THE MACHINE to bypass any interlock, overload, disconnect, or other
safety device.
(continued on the next page)
M-318A i
DON’T OPERATE EQUIPMENT if unusual or excessive heat, noise, smoke, or vibration
occurs. Report any excessive or unusual vibration, sounds, smoke, or heat as well as
any damaged parts.
MAKE CERTAIN equipment is properly grounded. Consult the National Electric Code
and all local codes.
DISCONNECT MAIN ELECTRICAL POWER before attempting repair or maintenance.
ALLOW ONLY AUTHORIZED PERSONNEL to have access to enclosures containing

electrical equipment.
DON’T ALLOW the operation or repair of equipment by untrained personnel.
DON’T REACH into any control or power case area unless electrical power is OFF.
DON’T TOUCH ELECTRICAL EQUIPMENT when hands are wet or when standing on a
wet surface.
REPLACE BLOWN FUSES with fuses of the same size and type as originally furnished.
ASCERTAIN AND CORRECT the cause of any shutdown caused by overloaded heaters
before restarting the machine.
KEEP THE AREA AROUND THE MACHINE well lighted and dry.
KEEP CHEMICAL AND FLAMMABLE MATERIAL away from electrical or operating

equipment.
HAVE THE CORRECT TYPE OF FIRE EXTINGUISHER handy when machining com-
bustible 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 GUARDS are in place and that all doors are closed
and secured.
TO REMOVE OR REPLACE any collet closer, it is necessary to remove the guard door.
Make certain that the door is returned in place before starting the machine.
DON’T OPEN GUARD DOORS while any machine component is in motion.
MAKE SURE chucks, closers, fixture plates and all other spindle-mounted work-holding
devices are properly mounted and secured before starting machine.
MAKE CERTAIN that all tools are securely clamped in position before starting machine.
REMOVE ANY LOOSE PARTS OR TOOLS in the work area before operating machine.
Always check the machine and work area for loose tools and parts especially after work
has been completed by maintenance personnel.
ii M-318A
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 LEVEL and the status of indicator lights before operating
the machine.
INSPECT ALL SAFETY DEVICES AND GUARDS to make certain that they are in good
condition and are functioning properly before the cycle is started.
CHECK SETUP, TOOLING, AND SECURITY OF WORKPIECE if the machine has been
OFF for any length of time.
DRY CYCLE a new setup to check for programming errors.
MAKE CERTAIN you are clear of any “pinch point” created by moving slides before
starting the machine.
DON’T OPERATE any equipment while any part of the body is in the proximity of a po-
tentially hazardous area.
DON’T REMOVE CHIPS with hands. Use a hook or similar device and make certain that
all machine movements have ceased.
BE CAREFUL of sharp edges when handling newly machined workpieces.
DON’T REMOVE OR LOAD workpieces while any part of the machine is in motion.
DON’T OPERATE ANY MACHINE while wearing rings, watches, jewelry, loose clothing,
neckties or long hair not contained by a net or shop cap.
DON’T ADJUST tooling or coolant hoses while the machine is running.
DON’T LEAVE tools, workpieces or other loose items where they can come in contact
with a moving component of the machine.
DON’T CHECK finishes or dimensions of workpiece near running spindle or moving

slides.
DON’T JOG SPINDLE in either direction when checking threads with a thread gage.
DON’T ATTEMPT to brake or slow the machine with hands or any makeshift device.
ANY ATTACHMENT, TOOL, OR MACHINE MODIFICATION not obtained from Hardinge

Inc. must be reviewed by a qualified safety engineer before installation.
USE CAUTION around exposed mechanisms and tooling especially when setting up. Be
careful of sharp edges on tools.
M-318A iii
DON’T USE worn or defective hand tools. Use the proper size and type tool for the job
being performed.
USE ONLY a soft-faced hammer on turret tools and fixtures.
DON’T USE worn or broken tooling on the machine.
MAKE CERTAIN that all tool mounting surfaces are clean before mounting tools.
INSPECT ALL CHUCKING DEVICES daily to make certain that they are in good operat-
ing condition. Replace any defective chuck before operating the machine.
USE MAXIMUM ALLOWABLE gripping pressure on the chuck. Consider the weight,
shape and balance of the workpiece.
USE LIGHTER THAN NORMAL feedrates and depth of cut when machining a
workpiece diameter that is larger than the gripping diameter.
DON’T EXCEED the rated capacity of machine.
DON’T LEAVE the machine unattended while it is operating.
DON’T CLEAN the machine with an air hose.
KEEP TOTE PANS a safe distance from machine. Don’t overfill the tote pans.
DON’T LET STOCK project past the back end of the collet closer or machine spindle
without being adequately covered and properly supported.
FOLLOW each bar feed manufacturer’s guidelines. For performance and safe applica-
tion, size and use feed tube bushings, pushers, and spindle liners according to bar feed
information.
MAKE CERTAIN that any bar feed mechanism is properly aligned with the spindle. If the
bar feed is a floor-mounted type, it must be securely bolted to floor.
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 machine when opening and closing the coolant guard door and any access
covers.
FOR YOUR PROTECTION - WORK SAFELY
iv M-318A
- CONTENTS -
CHAPTER 1 - INSTALLATION INSTRUCTIONS

Placing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
Leveling the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Grounding the Machine . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Earth Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
System Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
Pneumatic (Air) Connection . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Lubrication Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Cutting Fluid (Coolant) . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
ST216/ST220 High Speed Spindle Option Motor Cooling Module . . . . . 1 - 9
Non-Metallic Materials Found in Hardinge Machine Construction . . . . . . 1 - 10
CHAPTER 2 - POWER-UP PROCEDURE

Machine Power-Up Procedure . . . . . . . . . . . . . . . . . . . . . . 2 - 1
Coolant Guard Door Safety Interlock . . . . . . . . . . . . . . . . . . . 2 - 2
Power-Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2
CHAPTER 3 - PNEUMATIC (AIR) FACILITIES

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Air Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
Drain the Filter/Regulator and Coalescing Filter Bowls . . . . . . . . . . 3 - 2
Replace the Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
Replace the Air Control Assembly Components. . . . . . . . . . . . . . 3 - 3
Replace the Pressure Switch . . . . . . . . . . . . . . . . . . . . . . 3 - 4
Air Valve Compartment . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
CHAPTER 4 - COOLANT FACILITIES

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
Cutting Fluids (Coolant) . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
Water-Based Coolants . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
Concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
pH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
Water Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
Coolant Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
Coolant Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
Removing Chips and Shavings . . . . . . . . . . . . . . . . . . . . . 4 - 3
Cleaning the Reservoir and Filters . . . . . . . . . . . . . . . . . . . . 4 - 4
Replacing the Flexible Copper Lines or In-Line Valves . . . . . . . . . . 4 - 5
Tool Plate Coolant Facilities . . . . . . . . . . . . . . . . . . . . . . . 4 - 6
Replacing the Coolant Pump . . . . . . . . . . . . . . . . . . . . . . 4 - 6
Coolant Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
M-318A v
CHAPTER 5 - LUBRICATION
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
Lubrication Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
Lubricator Consumption . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
Lubricator Refill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2
Fill the Lubricator Tank . . . . . . . . . . . . . . . . . . . . . . . 5 - 2
Correct Low Lubricator Condition . . . . . . . . . . . . . . . . . . . 5 - 2
TRABON® Lubricator Reservoir and Divider Valves (Feeders) . . . . . . . 5 - 3
Change System Filter . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3
Prefill and Purge (Prime) the Lubrication System of Air. . . . . . . . . 5 - 3
Replace Master Divider Valve and/or Secondary Feeders . . . . . . . 5 - 5
Replace the Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
Clean the Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
Clean Tramp Oil Line . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
CHAPTER 6 - MISCELLANEOUS
Control Battery Unit(s) . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1
Standard Spindle Cooling (Chiller) System . . . . . . . . . . . . . . . . 6 - 2
Fill Spindle Cooling Unit Tank . . . . . . . . . . . . . . . . . . . . 6 - 2
Clean and Refill Spindle Cooler Tank . . . . . . . . . . . . . . . . . 6 - 2
ST216/ST220 High-Speed Spindle Cooling Module and Lubricator . . . . . 6 - 3
Fill Spindle Motor Coolant Unit Tank . . . . . . . . . . . . . . . . . 6 - 4
Clean and Refill High-Speed Spindle Cooler Tank . . . . . . . . . . . 6 - 4
Refrigerant Cooling Unit . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
Fill Air/Oil Lubricator Tank (VOGEL) . . . . . . . . . . . . . . . . . 6 - 5
Clean and Refill the Air/Oil Lubricator Tank . . . . . . . . . . . . . . 6 - 5
Change Air/Oil Lubricator Filter . . . . . . . . . . . . . . . . . . . . 6 - 6
“Bleed” Air/Oil Lubricator Mixing Block . . . . . . . . . . . . . . . . 6 - 6
Spindle Toggles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7
Lubricating the Toggles . . . . . . . . . . . . . . . . . . . . . . . 6 - 7
Replacing the Toggles . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7
Adjusting the Toggle Force. . . . . . . . . . . . . . . . . . . . . . 6 - 10
Worklight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11
APPENDIX ONE
Preventive Maintenance Scheule . . . . . . . . . . . . . . . . . . . . A1 - 1
Adhesives and Sealers . . . . . . . . . . . . . . . . . . . . . . . . . A1 - 2
Recommended Spare Parts List . . . . . . . . . . . . . . . . . . . . . A1 - 2
APPENDIX TWO
Photographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2
vi M-318A
- NOTES -
M-318A vii
- NOTES -
viii M-318A
CHAPTER 1 - INSTALLATION INSTRUCTIONS
Call the Hardinge service department at (800) 424-2440 or (607) 734-2281 to schedule the final in-
stallation and inspection of this machine. A Hardinge Field Service Engineer will visit your plant, at no
charge, to test run this machine. He runs a designed test program and will not set-up or make parts.
The following steps must be taken before the engineer arrives:
A. Place and level the machine.
If the machine will have the bar feed option, secure the machine.
B. Clean the machine.
C. Ground the machine.
D. Connect electrical source to the machine.
E. Connect pneumatic (air) source to the machine.
PLACING THE MACHINE

The Swiss-Turn Lathe does not require a special foundation. A substantial wood or concrete floor,
which is fairly flat and of sufficient strength to support the machine is satisfactory. Do not locate the
machine near equipment that causes vibration.
It is not necessary that the machine be set perfectly level unless a bar feed is used with the ma-
chine. However, the machine should be reasonably level, within .13 inch [3.3 mm] in the machine foot-
print, to allow the way lube oil to be collected at the right end of the machine.
To set the machine in place:

1. Leave the machine on the skid and move it to the installation site.
2. Remove the coolant tank, ground rod, and any parts boxes from the skid.
3. Unthread the shipping screws that secure the hold-down brackets to the skid. Remove
the front hold-down bracket for clearance of the coolant reservoir (tank).
Loosen the screws that mount the remaining hold-down brackets; raise the brackets all
the way up to clear the skid and tighten the screws just enough to hold the brackets up.
4. Leg 1, Figure 1.1, is set at the factory, it is not adjustable. Thread legs 4 and 5, all the
way up for clearance.
- NOTES -
There are two fork lift slots, 24 inches (609 mm) center to center, running from
front to rear through the bottom of the machine base. Lift the machine slowly to
make certain that the fork lift truck maintains its balance.
Raise the machine high enough that the machine’s feet clear the deck of the skid.
The machine is initially supported and leveled on legs 1, 2, and 3.
5. Lift the machine from the skid by using a fork lift truck and lower the machine in place.
6. Unlatch the left front access door in two places and remove it from the machine. Reach
up inside and unthread the screw that fastens the red coolant guard door bracket in
place. Remove the bracket and open the door.
M-318A 1-1
87.4
[2220.0]
74.5
Hold-Down [1892.3]
Bracket
66.9 Tramp-Oil
[1699.3] Pan
Hold-Down
Bracket
This leg is
NOT adjustable.
22.6
[574.0] 1 7.7
13.3
3 [195.6]
[337.8]
4 Spindle Centerline
0.6 2 5
[15.2] 7.8
4.5
[114.3] [198.1]
Typ.
8.5 2.1
[215.9] [53.3]
26.5
[673.1]
41.6
[1054.1] TI3908.cmx
Figure 1.1 - Swiss-Turn Lathe Footprin
LEVELING THE MACHINE

Unless the machine is to be used with a bar feed, it is not necessary that the machine be set per-
fectly level. However, it should be reasonably level to allow way lubrication (tramp) oil to be collected
at the right end of the machine.
Use either the splined spindle or a Z axis linear guide rail as a qualifying surface to level the ma-
chine within 0.025 inch per foot [0.635 mm per 305 mm]. Make sure that the bubble indicator or other
leveling device is parallel with the spindle centerline. If the machine is ever relocated, it must be totally
re-leveled per these instructions to assure axes alignments are maintained.
To level the machine:

1. Carefully lower the machine in place. The machine is firmly supported by three legs.
2. Place a bubble indicator on the splined spindle shaft or on a Z axis linear rail, parallel
with the spindle centerline, and level the machine within .13 inch [3.3 mm] in the ma-
chine footprint.
However; if the machine will have the bar feed option, use a tighter specification and the
same qualifying surface. Level the machine for a bar feed as follows:
A. At the front right end of the machine, press the top of both latches and turn them to
release the access cover. Lift the access cover from the machine.
B. Place the bubble indicator or other leveling device on the splined spindle shaft or a Z
axis linear rail parallel with the spindle centerline.
1-2 M-318A
- NOTES -
Level the machine within 0.025 inch per foot [0.635 mm per 305 mm].
The last threaded turn on each leg must be to make contact with the floor to re-
move any thread backlash in the leg.
Do not use legs 4 and 5, Figure 1.1, to level the machine. Neither leg should touch
the floor until the machine is level.
Check the height of the coolant tank to be certain that there is clearance with the
machine.
C. Thread or unthread legs 2 and 3 as necessary to level the machine within specifica-
tion.
D. Thread legs 4 and 5 down to support the machine, tight enough that the disk is un-
able to move or turn but not enough to effect machine level.
E. Check each of the first three legs legs to make sure that they are still in contact with
the floor and, then, check the machine for still being within level specification.
- NOTE -
To secure the machine, it may be more convenient to move the machine to drill the
holes and mount the expansion shields after the floor has been marked.
F. Secure the machine to the floor as follows:
1) Loosen the mounting screws that fasten the hold-down brackets and lower them to
the floor. If necessary, remove the hold-down bracket from the parts box and
mount it as the second bracket on the spindle end. Tighten the screws just enough
to hold the brackets.
2) Mark the floor at the center of the slots in the hold-down brackets.
3) Remove the hold down brackets from the machine.
4) Drill a .75 inch [19 mm] diameter hole, 4 inches [102 mm] deep at the mark.
5) Drive an expansion shield down into the hole until it bottoms. Refer to Figure 1.2.
6) Mount the hold down brackets to the machine.
7) Put a washer on the lag screw. Put the lag screw through the hold down bracket
and thread it into the expansion shield until it is tight.
3. Check to make certain that the machine is level within specification. When the machine
is within level specification, tighten the hold-down bracket mounting screws.
4. Roll the coolant tank into place and check the clearance. Adjust the height of the ma-
chine and re-level it as necessary.
M-318A 1-3
Lag Screw A. Mark floor at desired locations.
RF-0012119-04
B. Drill 0.75 [19.1] hole, 4.0 [29.4] deep.
Washer C. Drive expansion shield down to the
CN-0000132 bottom of the hole.
0.75 1.0
Hold Down Bracket [19.1] [25.4]
Concrete Floor
4.0
[29.4]
Expansion shield
RF-0012120
TI2928.
Dimensions are English [Metric]
Figure 1.2 - Lag Screw Floor Assembl
CLEANING THE MACHINE

- CAUTION -
Do not use compressed air to clean chips from the machine. Air pressure
forces dirt and other foreign matter past the seals and covers into the slides,
ball screws, and bearings. This will cause additional wear and will reduce
the life and accuracy of the machine.
After the machine has been properly located and leveled, remove all shipping grease, oil, and dirt
accumulated in transit. USE A CLOTH OR BRUSH WITH A GOOD GRADE OF PETROLEUM BASE
GREASE SOLVENT TO CLEAN THE MACHINE.
Use Clorox 409® cleaner to clean the coolant guard windows. Do not use benzene, leaded gaso-
line, acetone, or chlorinated solvents.
1-4 M-318A
GROUNDING THE MACHINE
- WARNING -
Improper grounding of the Hardinge CONQUEST® ST series lathe could re-
sult in damage to the control and severe electrical shock to personnel in the
event of an electrical fault. To properly ground the machine an Earth Ground
and a System Ground are required.
The minimum ground wire size for all machines is 8 AWG.
In general, there are two requirements for system grounding. They are as follows:
Earth Ground:
An earth ground assures that all voltages have the same reference base and that voltage potential,
in the event of circuit shorts or other malfunctions, is limited. This is accomplished by having a neutral
reference wire common to all voltage sources within the system.
Since safety requirements vary with locality, consult local codes which will take precedence over
the following guidelines. Earth ground connections in their order of effectiveness are as follows:
1. Effectiveness of continuous water pipe when properly buried will depend on conditions
of soil. When installed below permanent moisture level, the impedance of this type
ground is typically below 3 OHMS.
2. Effectiveness of man-made, driven or buried electrodes will depend on condition of soil.
When installed below permanent moisture level, the impedance of this type ground is
typically below 5 OHMS.
3. Other available electrodes, such as metal frames of buildings or metal well castings
must be well chosen, since they are substantially below 25 OHMS but exceed 5 OHMS.
Ground connections, wire, and electrodes should not exceed 5 OHMS, as measured from the
equipment ground stud through the primary electrode, through earth, to another independent elec-
trode, separated by 20 feet of earth. Additional ground should be installed when necessary to insure
that the impedance does not exceed 5 OHMS. The ohmic measurement should be made in terms of a
voltage-current relation, such as the current of a 120 volt, 100 watt lamp bulb.
The ground conductor connecting the ground stud to the chosen electrode should be of braid or
welding cable (equivalent to AWG #8 or larger). Braid or welding cable minimizes the resistance at
higher frequencies.
When longer lengths are required, use a larger size cable so that the resistance of the cable is less
than 0.075 OHMS. In general, the size must be rated to carry peak short-circuited current for maxi-
mum time duration without degrading the ground system, and must withstand any mechanical abuse
to which it may be exposed.
Interconnect all separate enclosures, control stations, pendant stations, conduits, and the like, to
implement and maintain safe ground continuity throughout all metallic components of the system.
This is always considered good practice and a locally regulated requirement.
M-318A 1-5
System Grounding:
A proper grounding arrangement prevents equipment damage and personal injury caused by an
electrical fault such as a short circuit. To accomplish this, the grounding setup must assure that all
voltages have the same reference base; and that, in the event of an electrical fault, the voltage poten-
tial is limited. The National Electrical Code recommends that:
250-51. Effective Grounding Path. The path to ground from circuits, equipment,
and metal enclosures for conductors shall (1) be permanent and electrically continu-
ous, (2) have capacity to conduct safely any fault current likely to be imposed on it,
and (3) have sufficiently low impedance to limit the voltage to ground and to facili-
tate the operation of the circuit protective devices.
The earth shall not be used as the sole equipment grounding conductor.*1
On the Swiss-Turn lathes, all electrical circuits and all non-current carrying metal parts of the con-
trol and the machine tool are interconnected by a series of ground wires attached to the ground bar lo-
cated in the bottom of the control case.
Attached to the shipping crate is an eight foot long, 5/8 inch round copper-covered steel rod, which
is the system grounding electrode, and a ground clamp. The ground connector used to connect the
machine ground block to the electrode must be a braid or welding cable equivalent to AWG #8 or
larger. (Braid or welding cable minimizes the resistance at higher frequencies). When longer lengths
are required, use a larger size cable so that the total resistance of the cable is less than .075 OHMS. In
general, the size must be rated to carry peak short-circuited current of maximum time duration without
degrading the ground systems, and must withstand any mechanical abuse to which it may be ex-
posed.
To establish an earth ground, the electrode must be driven into the ground to a depth of eight feet. If
the bottom is encountered at a depth of less than four feet, the electrode may be buried horizontally in
a trench.
*1 National Fire Protection Association, National Electrical Code Handbook 1996, Fifth Edition, Section 250-51.
1-6 M-318A
POWER CONNECTION
- NOTES -
Due to the variation of local electrical codes, Hardinge recommends that the local
utility supply company be consulted to determine exact service and wiring require-
ments.
Machines that require 380, 415, 460, and 575 voltage supply must have a supple-
mentary transformer. It is recommended that machines with 208 voltage supply
have a supplementary transformer also.
To connect the electrical source:

- WARNING -
Make certain that the disconnect switch is in the OFF position when working
in the power case or the control case.
1. Turn off the power source to the electric cable that leads to the machine.
2. Turn the disconnect switch to OFF before opening the power case door.
3. Unlock the power case door. Turn the dis-
connect switch while pulling the door
open. A
4. Make certain that the line side of discon-
nect switch “A”, Figure 1.3, and the
ground bar inside the case are set to have
the power source and ground line con-
nected. If the line side of the disconnect
switch has wire clamps, they must be
open so that the wires can be inserted.
5. Route the power cable into the power
case far enough to easily reach the switch
and the ground bar near it. Use a cable
clamp to secure the cable at the entrance TI2466.
to the power case. If the line side of the
disconnect switch has screws without wire Figure 1.3 - Disconnect Switch
clamps, fasten a 1/4 inch [6.5 mm] ring
clamp to each of the wires.
- CAUTION -
Do not apply power to the machine. Start up of the machine is conducted by
a Hardinge service engineer.
6. Connect the ground wire and power leads.
The electric power source is connected properly, i.e. phased correctly, when the coolant
pump actually circulates coolant upon start up and the spindle chiller (cooling) unit at the
rear of the machine also pumps chiller cooling fluid from its reservoir. Further verify cor-
rect electrical phase by checking correct rotation of fans or shafts of the various pumps.
A visual check of these components is important.
M-318A 1-7
PNEUMATIC (AIR) CONNECTION
The pneumatic filter/regulator and the coalescing filter are mounted at the rear of the machine on
the right side above the coolant pump. Supply an air line with proper fittings to the machine. Factory air
to the machine goes through the filter/regulator to control the air supply for the machine. A heavy-duty
air dryer may have to be added in the air line if the factory air has excessive moisture. The incoming air
line should have a minimum I.D. of 3/8 inch [9.5 mm]; however, if the air line is especially long, a larger
inside diameter hose may have to be installed. Connect the air line to the machine. Do not turn the air
source ON.
The Hardinge Service Engineer will check the incoming air line connection, turn the air valve ON,
and set the regulator at a consistent pressure from 65 psi to 80 psi [4.5 to 5.5 bars]; the upper pressure
setting is preferred, however, other applications may require a lower air setting. The air pressure
switch is preset at 60 psi [4.2 bars]. If the pressure falls below this, an alarm message appears on the
CRT and the program goes into E-Stop.
LUBRICATION OIL
The lubrication oils that Hardinge Inc. recommends for use on the machines have been thoroughly
tested and qualified. Other oils may not contain certain additive packages needed for proper lubrica-
tion and performance from the oil. The additive packages may include rust and corrosive inhibitors,
anti-wear compounds, defoamants, etc., which have been blended specifically for that application. Al-
though many companies offer “similar” oils, these oils may not contain the needed additives to ensure
maximum performance and protection of the Hardinge machines.
CUTTING FLUID (COOLANT)

Hardinge machine tools are designed using the latest technology and highest quality materials
available. However, due to the ever increasing number of cutting fluid (coolant) selections available, it
is impossible to test material compatibility with each and every coolant. Refer to Chapter 4 for informa-
tion regarding the coolant facilities on this machine. The two most popular types of cutting fluids are
cutting oils and water-based coolants.
- CAUTION -
Whenever cutting fluids are used, it is essential to follow the manufacturer’s
recommendations on the selection and maintenance for that particular fluid.
WATER-BASED COOLANTS:
Water-based coolants are a cutting fluid which, when improperly specified or maintained, can af-
fect the life of a machine and the quality of the parts made on it. Water-based coolants are designed to
suppress rusting, enhance cutting, increase tool life, promote heat dissipation, and be economical to
use.
Some water-based coolants may cause machine corrosion problems and be incompatible with ma-
chine components, especially if the fluid is not maintained correctly. Poorly maintained coolants may
result in rancidity, poor tool life, staining, rusting, foaming, etc., which affect machine performance
and may cause health problems such as dermatitis. Water-based coolants must be correctly specified
according to the machined materials and ensure compatibility with the machine’s components. Refer
to the list of common materials used in the manufacture of Hardinge machines which follows this sec-
tion.
1-8 M-318A
It is extremely critical to follow the coolant manufacturer’s recommendations when using a wa-
ter-based coolant. Maintaining coolants per the manufacture’s recommendations will increase the
machine’s useful life and will minimize corrosion, rusting, staining, etc., and health problems such as
dermatitis. At a minimum, the coolant maintenance should include daily checks and correction of cool-
ant concentration, a measure of coolant pH, and removal of any tramp oil from the machine sump.
To prepare the coolant system:

1. Roll the coolant reservoir (tank) into the opening under the front of the machine.
2. Connect the coolant hose to the fitting on the tank by pulling back on the knurled ring on
the quick-disconnect coupling, slipping the coupling over the fitting and releasing the ring
to secure the coolant hose. Check the connection to make certain that it is secure.
3. Adjust the skirting and check inside the work area to see that coolant will drain back into
the chip pan in the coolant reservoir.
4. Pour the coolant directly into the chip pan. Fill the tank with the approved coolant to the
FULL (approximately 15 gallons [57 liter]) line of the sight gauge.
5. Make any adjustments before powering up the machine and turning the coolant on.
6. Prime the coolant pump, if necessary, as follows:
A. Put a flexible piece of hose, approximately 16 to 18 inches [406.4 to 457.2mm] long,
over one of the headwall coolant nozzles.
B. Cut a 1 inch [25.4 mm] slot, 2 [50.8 mm] inches from the tip of the hose.
C. Put an air hose tip into the slot and point it toward the open end of the hose.
D. Activate the coolant in the headwall nozzle and turn the air on to create a vacuum
and draw the coolant through the system.
- NOTE -
A properly selected and maintained coolant, either oil or water based, will ensure
the best performance from the coolant and machine.
ST216/ST220 HIGH-SPEED SPINDLE OPTION

MOTOR COOLING MODULE
The high-speed spindle option requires a motor cooling module which is a closed-loop, self-con-
tained refrigeration cooling unit in line with the standard spindle cooling reservoir.
To prepare the motor cooling (chiller) module:

1. Roll the refrigeration cooling unit into place near the spindle coolant reservoir at the rear
of the machine.
2. Make the following connections between the machine and cooling module: the coolant
hoses to the fittings on the tank by pressing each hose into its fitting. Pull on the hoses
to check the connection to make certain that it is secure.
The electrical cable to the cooling module junction box by installing the green wire to the
ground stud and the black and white wires to the screws under corresponding wires.
3. Mix cooling fluid by selecting a good grade, ethylene glycol based, automotive coolant
and mixing it with demineralized/de-ionized water, 50-50 ratio (7 gallon capacity).
4. Check the coolant level and add coolant as necessary. Remove the filler cap; pour the
cooling fluid mixture into the reservoir; replace the filler cap and tighten.
M-318A 1-9
Non-Metallic Materials Typically Found in Hardinge Machine Construction:
nitrile polycarbonates
neoprene nylons
fluorocarbon rubber phenolic plastics
urethane polyethylene
silicone rubbers PVC
cork-nitrile composites PTFE (polytetrafluoroethylene)
polyurethane enamel
acetal plastics
- NOTES -
1 - 10 M-318A
CHAPTER 2 - POWER-UP PROCEDURE
- CAUTION -
The recommended operating temperature range is 50º to 114º F [7 to 46º C].
MACHINE POWER-UP PROCEDURE

- NOTE -
Follow the power-up procedure exactly as described in the steps that follow to en-
sure safe, accurate, and repeatable machine maintenance and operation.
1. Unlock, if necessary, and turn the main A
disconnect switch near the power case
door, ON.
B
- CAUTION -
Air filter/regulator bowl “C”, Figure
2.2, must be drained at least once a
day. If more frequent draining is
required, it may be necessary to
install an air dryer in the air line.
2. Open main air lock out valve “B”, Figure D
2.1, and drain the filter bowl by pressing
valve “C” sideways. Bowl “D”, drains auto- C TP2470A
matically.
Figure 2.1 - Machine Air Control Assembly
3. Check lubricant and coolant levels. Add
lubricant and coolant as required.
- CAUTION -
When pressing CONTROL ON pushbutton “F”, Figure 2.2, DO NOT press any
other CRT/MDI panel pushbuttons or keys until the Position or Alarm screen
is displayed. Some pushbuttons and keys have other control maintenance or
special operation functions.
4. Press the CONTROL ON pushbutton and wait until the display screen is on.
5. Pull Emergency Stop pushbutton “G” up and hold while pressing Emergency Stop RE-
SET pushbutton “H” [31], Figure 2.2.
Release the Emergency Stop pushbutton.
6. Open and close the coolant guard door to perform the guard door switch verification.
7. If necessary, enable the bar feed system.
8. Check the operator’s control panel, the machine is now ready for operation. Refer to Op-
erator’s manual (M-317) to review the control status or when axes motion is required.
M-318A 2-1
F
H
TI2842
I
TP2450.
Figure 2.2 - Operator's Control Panel
COOLANT GUARD DOOR SAFETY INTERLOCK

Machines are equipped with a coolant guard door mechanical interlock. When the machine is exe-
cuting a part program in Automatic mode, the coolant guard door is mechanically locked in the closed
position. The guard door can be opened when the program cycle is finished.
POWER-DOWN PROCEDURE
1. Be sure Cycle Start is not active. Cycle Start pushbutton “I” [52], Figure 2.2, indicator
light is OFF.
2. Be sure that program execution has been completed and that the spindle and slides are
stationary.
3. Press EMERGENCY STOP pushbutton “G”, Figure 2.2.
4. Press CONTROL OFF pushbutton “E”.
5. Turn main air lock out valve “B”, Figure 2.1, OFF. Lock out the valve.
6. Turn the main disconnect switch OFF. Lock out the electric power source.
2-2 M-318A
- NOTES -
M-318A 2-3
- NOTES -
2-4 M-318A
CHAPTER 3 - PNEUMATIC (AIR) FACILITIES
INTRODUCTION
Factory air to the Swiss-Turn lathe goes through a heavy-duty filter/regulator system to set the air
pressure and remove contaminants before they get into the machine air supply. A coalescing filter is
mounted after the pressure switch manifold to remove additional water vapor and oil. If the factory air
has excessive moisture, a heavy-duty air dryer must be added to the incoming air line. An optional air
drip leg can be mounted in line.
The incoming air line must have a minimum inside diameter (i.d.) of 3/8 inch [9.5 mm] to support an
air volume requirement of 5 to 6 scfm [142 to 170 lm]; however, if the air line is especially long, a larger
i.d. hose may have to be installed. Machines with air operated options may require a higher volume of
air.
Open the main air valve and set the regulator at a consistent pressure from 65 psi to 80 psi [4.5 to
5.5 bar]; the upper pressure setting is preferred, however, other applications may require a lower air
setting. The air/oil lubricated machines require an incoming air line pressure of 80 psi [5.5 bar]. The air
pressure switch is preset at 60 psi [4.1 bar]. If the pressure falls below this, an alarm message appears
on the CRT and the program goes into E-Stop.
TP2470A
Figure 3.1 - Air Control Assembly
POWER-DOWN PROCEDURE
When the air system’s components require maintenance, the machine must be powered down. A
detailed procedure to power down the machine appears in Chapter 2 - Power-Up Procedure.
1. Be certain that “Cycle Start” is not active. Pushbutton light is OFF.
2. Be sure that the program has been completed and that the spindle and slides are sta-
tionary.
3. Press EMERGENCY STOP pushbutton.
4. Press CONTROL OFF pushbutton.
5. Close main air lock out valve. Lock out the air valve.
6. Turn main disconnect switch OFF. Lock out the electric power source.
M-318A 3-1
AIR CONTROL ASSEMBLY
The Wilkerson air control assembly, Figure 3.1, is located at the rear of the machine on the right
side above the coolant pump. It consists of a main air lock out valve, filter/regulator, manifold block
with pressure switch, and a coalescing filter. The air system distributes air to: 1) air purge the
headstock or air/oil spindle lubrication, 2) the main air blast which cleans parts and tool tips, 3) operate
the parts catcher, and 4) operate an automatic door. Other regulators and switches are added to this
assembly as air options are added to the machine.
Connect the air supply line to the air lock out valve. The air volume requirement is 5 to 6 scfm [142 to
170 lm]. Open the air lock out valve and then the regulator knob must be set to a consistent air pres-
sure between 65 psi and 80 psi [4.5 to 5.5 bar]; the higher air pressure (80 psi [ 5.5 bar]) is preferred for
machines with air/oil spindles.
- WARNING -
Do not attempt to block or look into the air port at the bottom of the air lock
out valve while releasing air.
When the air lock out valve is between the ON and OFF location, it releases the internal air pres-
sure from the machine.
DRAIN THE FILTER/REGULATOR AND COALESCING FILTER BOWLS
- CAUTION - D
Unless an automatic draining
system is used, air filter bowl “B”
must be drained at least once a day.
If more frequent draining is
required, it may be necessary to
install an air dryer on the air line.
Drain the filter/regulator bowl daily by pressing the C
manual FLEX-DRAIN® petcocks sideways; the co-
alescing filter has an automatic drain, however, occa- A
sionally check its bowl. If a moisture problem exists, B
add a heavy-duty air dryer to the incoming air line. TP2470A
Figure 3.2 - Air Filter Bowls
3-2 M-318A
REPLACE THE FILTERS
Drain the filter/regulator bowl daily and check the air system bowls once a week for contaminates. If
the sight gauge on the coalescing filter head is red, change the filter. The bowls are held in place by an
outer protective shell.
1. Power down the machine. Make certain that the air lock out valve is OFF.
2. Drain any water from the bottom of the filter/regulator and coalescing filter bowls.
3. Pull down on black latch “C”, Figure 3.2, on the side of the outer shell of the bowls.
Twist the shell counterclockwise to release it. Do not use excessive force to remove ei-
ther bowl.
4. Wipe the bowl clean with a lint-free cloth and check the O-ring for damage. Replace the
O-ring and/or bowl if necessary.
5. Clean or replace the filters as necessary. To release the filter, unscrew the nylon fixture.
Thread the new filter on the nipple until it is tight.
6. Mount the bowl on the head as follows:
A. Put the plastic bowl into the shell.
B. Align the bowl in the head and press the shell up into place. Rotate the shell clock-
wise until the latch “clicks” to seat the O-ring.
C. Pull down on the bowl to confirm that the bowl is in place before turning the air lock
out valve ON.
7. Power up the machine and turn the air lock out valve ON. Set the regulator to 80 psi
[5.5 bar] and check for air leaks. Correct any air leaks as necessary.
8. Set the regulator below 60 psi [4.2 bar] to test the pressure switch. The control will go
into an Emergency Stop condition.
9. Set the regulator to an operating pressure between 65 psi to 80 psi [4.5 to 5.5 bar].
10. Press the E-STOP RESET pushbutton if it is still necessary to clear “1017 Main Air
Pressure Low” alarm message from the CRT.
11. Check the air system bowl for contamination, moisture, or air leaks and correct any
problems as necessary.
REPLACE THE AIR CONTROL ASSEMBLY COMPONENTS

Any of the air control assembly components can be replaced if they become damaged. The air con-
trol assembly can also be replaced as a unit.
2. Disconnect the main air line from the air lock out valve.
3. Unthread the screw and pull the electric plug straight up from the top of the pressure
switch.
4. Disconnect the air line(s) from the air manifold.
5. Unthread the screws and remove the air assembly unit from the panel.
- NOTE -
The air control assembly components are fastened together with taper railed
blocks.
6. Loosen, but do not remove, the screw in the taper railed block on either side of the com-
ponent being replaced. Carefully slide the component out of the blocks.
M-318A 3-3
7. Make certain that the O-rings are in place and mount the new component between the
taper railed blocks. Tighten the screw in each block.
8. Mount the air assembly unit on the panel. Tighten the screws that fasten it in place.
- NOTE -
Use just enough sealant to secure the fitting when fastening the air lines to the
manifold((s). Do not apply sealant to the first few threads
9. Fasten the air line(s) to the manifold.
10. Connect the electric plug to the top of the of pressure switch. Thread the screw into the
pressure switch to secure the plug.
11. Connect the main air line and turn the air source on.
12. Power up the machine. Set the regulator to an operating pressure between 65 psi to 80
psi [4.5 to 5.5 bar].
REPLACE THE PRESSURE SWITCH

Pressure switch “D”, Figure 3.2, is designed to send a signal to the control and an alarm message
appears on the CRT when the air pressure falls below 60 psi [4.2 bar].
2. Unthread the screw that holds the electrical plug to the top of the switch. Pull the plug
straight up to remove it from the switch.
3. Unthread the pressure switch from the manifold. The switch is tightened to the manifold
with light torque pressure, however, a wrench may be necessary to unthread it.
- NOTE -
Use just enough sealant to secure the fitting when fastening the pressure switch to
the manifold. Do not apply sealant to the first few threads
4. Thread a new pressure switch on the manifold and only tighten it to 50 in/pounds
[5.6 N•m].
5. Connect the electric plug to the pressure switch. Secure the plug with the screw.
6. Power up the machine. Set the regulator to an operating pressure between 65 psi to 80
psi [4.5 to 5.5 bar].
3-4 M-318A
AIR VALVE COMPARTMENT
The air valve compartment is located high on the left end of the machine. It contains manifolds of air
blocks and optional valves and/or a regulator. Air for the ST216/ST220 High-Speed Spindle Lubrica-
tion in the air over oil lubrication system is controlled in this compartment.
Other than setting the air pressure in the air/oil lubrication system, there is no maintenance in the
compartment. The air regulator should be set at 40 psi [2.7 bar] with air flowing through the head bear-
ings; it is preset at the factory and should not require adjustment.
To set the air regulator:

1. Make certain that the machine is power
up and that the air is turned on with the
spindle running at approximately 1000
rpm.
2. Unthread the screws and lift off the air
valve compartment access cover at the
left end of the machine.
3. Verify that the main air regulator is set at
80 psi [5.5 bar].
4. Pull (lift) regulator knob “E”, Figure 3.3, E
out. Adjust the air pressure by twisting
(turning) the regulator knob until the speci-
fied pressure is met while air flows
through the system bearings.
5. After the pressure is set, align and push
the regulator knob in.
6. Mount the air valve compartment access TP2475.
cover. Continue with maintenance or oper-
ation of the machine. Figure 3.3 - Air Valve Compartment
TP3145
TP3146.
Figure 3.4 - Air Panel with X- and Z2-Axes Figure 3.5 - Air Valve Compartment Since
Air Blast Valves June 1998 w/ One Air Blast Valve
M-318A 3-5
- NOTES -
3-6 M-318A
CHAPTER 4 - COOLANT FACILITIES
INTRODUCTION
The Swiss-Turn lathes have a coolant (cutting fluid) recirculating system for either oil-based or wa-
ter-based coolant. The system consists of a reservoir (tank) with screens, a quick-disconnect cou-
pling, a three-quarter [.50 kW] horsepower electric pump, flexible copper lines (tubing) on the
headwall, brass directional balls on the tool plate, and directional balls on the back end tool slide.
Coolant is fed to the work area through the headwall hoses. Most of the coolant drains into the tank
through the chip pan.
Clean the pan of chips and then pour the coolant directly into the pan. Fill the coolant reservoir with
the selected coolant to the FULL (approximately 15 gallon [57 liter]) line of the sight gauge on the tank.
The coolant system is always active and the control panel pushbuttons act counter to the program.
That is, when the program calls for coolant and coolant is not wanted, the coolant can be shut off by
pressing the COOLANT pushbutton. The opposite is also true. If coolant is not programmed and it is
needed, coolant can be activated by pressing the COOLANT pushbutton. If coolant flow has not been
activated by the program, pressing COOLANT will start coolant flow even though an M08, M13, or
M14 has not been programmed. However, if the program is repeated, the pushbutton must be
pressed again to activate the coolant each time the program is run.
Each of the copper lines and the directional brass balls on the tool plate directs coolant to the
workpiece and tool tips. Liquid flow to the nozzle is controlled by the COOLANT control pushbutton or
by each in-line valve that connects the lines to the square coolant-carrying tubing on the headwall.
CUTTING FLUIDS (COOLANT)

Hardinge machine tools are designed using the latest technology and highest quality materials
available. However, due to the ever increasing number of cutting fluid (coolant) selections available, it
is impossible to test material compatibility with each and every coolant. The two most popular types of
cutting fluids are cutting oils and water-based coolants.
- CAUTION -
Whenever cutting fluids are used, it is essential to follow the manufacturer’s
recommendations on the selection and maintenance for that particular fluid.
Water-Based Coolants:
Water-based coolants are a cutting fluid which, when improperly specified or maintained, can af-
fect the life of a machine and the quality of the parts made on it. Water-based coolants are designed to
suppress rusting, enhance cutting, increase tool life, promote heat dissipation, and be economical to
use.
Some water-based coolants may cause machine corrosion problems and be incompatible with ma-
chine components, especially if the fluid is not maintained correctly. Poorly maintained coolants may
result in rancidity, poor tool life, staining, rusting, foaming, etc., which affect machine performance
and may cause health problems such as dermatitis. Water-based coolants must be correctly specified
according to the machined materials and ensure compatibility with the machine’s components. Refer
to the list of common materials used in the manufacture of Hardinge machines which follows this sec-
tion.
M-318A 4-1
It is extremely critical to follow the coolant manufacturer’s recommendations when using a wa-
ter-based coolant. Maintaining coolants per the manufacture’s recommendations will increase
the machine’s useful life and will minimize corrosion, rusting, staining, etc., and health prob-
lems such as dermatitis. At a minimum, the coolant maintenance should include daily checks and
correction of coolant concentration, a measure of coolant pH, and removal of any tramp oil from the
machine sump.
Concentration:
The coolant concentration should be checked and corrected on a daily basis using a refractometer.
The refractometer is a hand held optical device that gives a fairly reliable reading. However, its accu-
racy can be impaired by tramp oils, cleaners, and other contaminants.
- NOTE -
The refractometer does not necessarily display a reading in fluid concentration. A
conversion factor or chart, which may vary from coolant to coolant and is supplied
by the coolant manufacturer, may be required to convert the refractometer reading
to the coolant concentration.
Proper concentration control is essential for optimal tool life, corrosion control, and inhibiting bacte-
rial growth. Water soluble coolants lose water by evaporation during normal operating conditions
which tends to increase the coolant concentration over a normal work shift. The coolant concentration
must be checked each day.
The coolant concentration must be kept within the specified range determined by the coolant man-
ufacturer. Failure to maintain the coolant concentration within this range may result in poor perfor-
mance from that fluid. Lean concentrations can lead to rust, rancidity, short tool life, and other
problems. Rich concentrations can result in foam, residues, health problems such as dermatitis, and
increased coolant costs.
pH:
The pH is a measure of the acid or alkaline characteristics of the fluid. There are two common meth-
ods used to determine the pH. One method is the use of pH indicator paper and the other is a pH me-
ter.
Water-based coolants are designed to run within a pH range determined by the manufacturer. The
pH of water-based coolants typically runs on the alkaline side (greater than 7) of the pH scale.
Water Quality:
The water quality is also an important factor toward achieving optimum coolant performance and
longevity. Water that contains excessive dissolved minerals (hard water), bacteria, and other impuri-
ties can have adverse affects on the coolant selected. An indication of water related problems is the
formation of a soap like scum which adheres to sumps, filters, etc. It is best to consult with your coolant
manufacturer representative to determine your requirements.
- NOTE -
A properly selected and maintained cutting fluid, either cutting oil or water-based
coolant, will ensure the best performance from the cutting fluid and the machine.
4-2 M-318A
COOLANT TANK
The coolant system has the capacity to hold 15 U.S. gallons (57 liters) of coolant. The coolant level
should not be allowed to fall below the sight gauge on the coolant tank. The coolant tank should be
drained and cleaned at least every six months or whenever the type or brand of coolant is changed.
More frequent cleaning may be required if the material being machined contaminates the coolant.
Open the front coolant guard door and pour the required amount of coolant directly down into the
coolant tank to fill the coolant tank. Either water-based or oil-based coolant may be used.
COOLANT LINES
Coolant can be directed onto the tool and workpiece with the flexible copper lines (tubing) and tool
plate brass balls. Manual control of coolant flow from the coolant tubing is controlled by a valve on
each hose. The tubes can be positioned however necessary to direct coolant where it is needed.
When the coolant facilities require maintenance, the machine must be powered down. A detailed
procedure to power down the machine appears in Chapter 2 - Power-Up Procedure.
Power-Down Procedure
1. Be certain that “Cycle Start” is not active. Pushbutton light is off.
2. Be sure the program has been completed and that the spindle and slides are stationary.
5. Turn main air lock out valve OFF.
6. Turn main disconnect switch OFF.
REMOVING CHIPS AND SHAVINGS

The chip pan/coolant reservoir (tank) is mounted on wheels and has a quick-disconnect coupling
so that it can be moved from the machine in several directions.
- WARNING -
Use a rake and suitable container to remove metal chips and shavings from
the chip pan. Injury may result from attempting to remove chips without a
rake. Dispose of the chips and shavings in an environmentally safe manner.
Chip removal procedure:

1. Power down the machine.
2. Wait a minute to allow coolant to drain back into the tank.
3. Locate the quick-disconnect coupling on the back of the tank. Pull the knurled ring on
the coupling back and release the coolant hose from the fitting on the tank.
4. Lift the left-end, low, chip access cover straight up then out to remove it. Remove as
many chips as possible through this opening from the coolant tank.
Rake the chips into a suitable container and dispose of them properly.
5. Move the tank into an area that is convenient to remove the metal chips and shavings.
M-318A 4-3
6. Return the tank to the opening under the front of the machine.
7. Reconnect the coolant hose to the fitting on the tank by pulling back on the knurled ring,
slipping the coupling over the fitting, and releasing the ring to secure it.
Mount the chip access cover on the low, left end of the machine.
8. Adjust the skirting and check inside the work area to see that coolant will drain into the
chip pan. Make adjustments before powering up the machine and turning the coolant on.
CLEANING THE RESERVOIR AND FILTERS

Clean the coolant reservoir (tank) at least once every six months or more frequently if the materials
being cut contaminate the coolant. Clean the reservoir whenever changing the type or brand of cool-
ant. If a chip conveyor is used, follow the directions provided by the manufacturer.
To clean the reservoir and filters:

2. Wait a minute to allow the coolant to drain into the tank.
3. Pull the knurled ring on the quick-disconnect coupling back and release the coolant hose
from the fitting on the tank.
4. Lift the left-end, low, chip access cover straight up then out to remove it. Remove as
many chips as possible through this opening to the coolant tank.
- WARNING -
Use a rake and suitable container to remove metal chips and shavings from
the chip pan. Injury may result from attempting to remove chips without a
rake. Dispose of the chips and shavings in an environmentally safe manner.
5. Move the tank into an area that is convenient to remove the metal chips and shavings.
Rake the chips into a suitable container and dispose of them properly.
6. Place a shallow pan under the tank drain on the right end of the tank. Remove the pipe
plug and drain the coolant from the reservoir.
7. Lift the sump cover and screens from the tank.
- WARNING -
Wear protection and be careful when removing coolant, metal chips, and
shavings from the reservoir.
8. Remove any coolant still in the reservoir and wipe it clean.
9. Be aware of how the filter assembly is mounted in the reservoir. Lift the filter assembly
from the frame.
10. Shake out the metal chips and wipe the filter assembly clean.
11. Wash the reservoir and filter assembly with a cleaner recommended by the coolant
manufacturer to remove any bacterial contamination. Flush the cleaner from the reser-
voir and clean it as recommended.
12. Apply pipe sealant to the pipe plug and thread it into the tank drain.
- NOTE -
Do not force the filter assembly into the frame. There is only one way for it to fit.
13. Replace the filter assembly in the frame in the tank. Put the screens and sump cover in
place in the tank.
14. Roll the tank into the opening under the front of the machine.
4-4 M-318A
15. Reconnect the coolant hose to the fitting on the tank by pulling back on the knurled ring,
slipping the coupling over the fitting, and releasing the ring to secure it.
16. Check inside the work area and adjust the skirting to see that coolant will drain into the
chip pan. Mount the chip access cover on the low, left end of the machine.
17. Pour the coolant directly into the chip pan. Fill the reservoir with the selected coolant to
the FULL (approximately 15 gallon [57 liter]) line of the sight gauge.
18. Make any adjustments before powering up the machine and turning the coolant on.
REPLACING THE FLEXIBLE COPPER LINES OR IN-LINE VALVES

Flexible copper lines (tubing) “A”, Figrue 4.1, can be set at any length, after powering down the ma-
chine, by flexing and pointing the tubing as necessary. If length is a consideration, change copper
tubes or cut the tubing.
To replace an adjustable hose or in-line valve:

2. Unthread the threaded link of the copper
line from the valve.
3. Unthread the valve from the square cool-
ant-carrying tubing when it has to be re-
moved.
4. Thread the valve into the headwall tubing
and thread the copper line into the valve.
Use pipe sealant on the fitting threads A
when replacing either the valves or copper
lines.
5. Adjust the length and angle of the copper
tubing for the best coolant direction.
6. Power up the machine and adjust the
coolant flow as necessary.
TP2274.
Figure 4.1 - Coolant Lines
M-318A 4-5
TOOL PLATE COOLANT FACILITIES
Each tooling station has an adjustable brass ball to direct coolant to the tool or workpiece. Coolant
to the tool plate stations is routed through a distribution block, valve and adapter block through the tool
plate to the adjustable directional balls. Loosen the mounting screw to adjust the coolant direction.
To clean/replace the tool plate brass ball(s):

1. Power down the machine and open the coolant guard door.
- NOTE -
Brass balls are available without openings to seal off coolant or that can be altered
to fit specific needs.
2. Carefully unthread the brass ball mounting screw. Be prepared to catch the screw and
brass ball from the tool plate.
3. Wipe clean the brass ball or replace it. Wipe each part dry with a lint free cloth and
check them for burrs. Stone the parts smooth and clean as necessary.
4. Mount the brass ball and tighten the mounting screw after setting ball direction.
5. Set the flexible copper line (tubing) direction.
6. Close the coolant guard door and power up the machine.
REPLACING THE COOLANT PUMP

The coolant pump is located on a shelf at the rear of the machine. The three-quarter [.50 kW] horse-
power motor draws coolant from the reservoir (tank) and pushes it to the headwall copper tubes and
tool plate openings.
2. Wait a minute to allow the coolant to drain
into the tank.
3. Pull the knurled ring on the quick-discon-
nect coupling and release the coolant
hose from the fitting on the tank.
4. Unthread the four bolts and remove the
flat washers and lock washers to loosen
the coolant pump from the shelf.
5. Unthread the screws to the electrical junc-
tion box cover on the pump and remove it
to gain entrance to the wires.
6. Make a diagram of the electrical wire con-
nections. This diagram will be important to
follow when connecting the replacement
pump. TP2470.
7. Disconnect the wires and remove the lead
cable from the junction box. Figure 4.2 - Coolant Pump
8. Remove the coolant pump from the shelf.
- NOTE -
Do not cut the hoses unless the fittings do not turn when the hose clamps are
loosened. There is enough hose if it is necessary to cut them.
9. Loosen the clamps on the hoses so that the fittings can be removed from the pump and
mounted on the new pump.
4-6 M-318A
10. Attach the coolant hoses to the pump fittings. Tighten the clamps on the hoses.
11. Feed the hose with the quick-disconnect coupling through the opening while placing the
pump on the shelf. Check to make certain that the coolant hoses are not kinked.
12. Feed the lead cable into the junction box and connect the wires per the diagram from
step #6. Make certain that the gasket is fitted and fasten the junction box cover in place.
13. Use the bolts, flat washers, and lock washers to secure the pump.
14. Pull the knurled ring on the quick-disconnect coupling back, slip the coupling over the
tank fitting, and release the ring to secure the hose. Put the tramp oil pan in place.
15. Power up the machine and check the coolant flow. Further verify the coolant flow by
checking correct rotation of the coolant pump. A visual check of this pump is important.
Prime the coolant pump, if necessary, as follows:
A. Put a flexible piece of hose, approximately 16 to 18 [406.4 to 457.2mm] inches long,
over one of the headwall copper tubes.
B. Cut a 1 inch [25.4 mm] slot, 2 [50.8] inches from the tip of the hose.
C. Put an air hose tip into the slot and point it toward the open tip of the hose.
D. Activate the coolant in the headwall nozzle and turn the air on to create a vacuum
and draw the coolant through the system.
16. Put the coolant pump access cover in place and fasten it with its screws.
CYLINDER OPERATED COOLANT SOLENOID VALVES

The coolant solenoid valves control coolant flow to the headwall, tool plate, and the optional back
tool slide and are located on a manifold just inside the rear access cover. They are air actuated by
electrical solenoid valves in the air valve compartment at the left end of the machine.
The coolant valves or the plug where the optional
back tool slide would be are as follows: C
A
A. Headwall
B. Back tool slide
C. Tool plate
The coolant comes directly from the coolant pump
through hose “D”, into the valve manifold.
B
There is no maintenance to the control valves;
however, if they become damaged, replace them as D
a unit. Power down the machine and wait a minute for TP2467.
coolant pressure to subside while unthreading the

screws and lifting off the rear access cover. Loosen Figure 4.3 - Coolant Solenoid Valves
the hose clamp(s) and unthread the fitting and con-
nection. Disconnect the air hose and unthread the air hose fitting. Some applications require the re-
moval of the black cylinder to remove the vvalve body from the manifold. Replace the coolant control
valve. Thread in the air hose fitting and reconnect the air hose; thread in the coolant hose connection
and fitting and tighten the coolant hose clamp. Power up the machine and seal any leaks as neces-
sary. Mount the rear access cover.
M-318A 4-7
- NOTES -
4-8 M-318A
CHAPTER 5 - LUBRICATION
INTRODUCTION
Lubrication is accomplished through a Lubriquip Inc. TRABON® progressive distribution system for
the ball screws and the linear guideways. Lubrication for the optional 12,000 rpm high-speed spindle,
a VOGEL® lubricator, is described in Chapter 6.
The lubricator is active during AUTO cycle and
only has periodic cycles during other modes. When
the lubrication system requires maintenance, the
machine must be powered down. A detailed proce-
dure to power it down appears in Chapter 2 -
Power-Up Procedure.
Power-Down Procedure
1. Be certain that “Cycle Start” is not active.
The pushbutton light should be off.
2. Be sure that the program has been com-
pleted and that the spindle and slides are
stationary.
5. Turn main air lock out valve OFF. TP2464
6. Turn main disconnect switch OFF. Figure 5.1 - Lubricator
LUBRICATION OIL
The oils that Hardinge Inc. recommends for lubrication use on the machines have been thoroughly
tested and qualified. Other oils may not contain certain additive packages needed for proper lubrica-
tion and performance from the oil. The additive packages may include rust and corrosion inhibitors,
anti-wear compounds, defoamants, etc., which have been blended specifically for that application.
Although many companies offer “similar” oils, these oils may not contain the needed addi-
tives to ensure maximum performance and protection of the Hardinge machines.
LUBRICATOR CONSUMPTION
- NOTE -
When servicing any part of the machine, inspect the lubrication lines in that area
for wear, abrasion, or kinking and replace the worn line(s) as necessary.
The run time for one full lubricator reservoir (tank) is approximately 82 hours. It should be noted that
all times are approximate and that variations on an individual machine could be up to ±10% from the
time listed. If actual lubrication consumption is greater or less than the acceptable range given, check
the system for leaks, kinked hoses, oil type, and TRABON master and secondary divider valves (feed-
ers).
The reservoir contains approximately 5.4 liters (5 quarts) of Mobil Vacuoline® #1405 (ISO 32) oil
when filled. The distribution blocks meter the amount of oil used per cycle. Oil is sent through the sys-
tem at 3 minute intervals by a motor-driven gear pump. The pump cycle time is controlled by machine
software and is preset at Hardinge.
M-318A 5-1
The machine software detects the following information:
A. Pump malfunction
B. Defective cycle switch
C. Plugged main lines
D. Broken master block oil supply line.
If the cycle software senses a failure in the lubrication system, a “Way Lube Fault, 5 Minutes to
Shutdown” message will be displayed and setup mode (Block by Block) is activated to allow the tool to
be moved from the workpiece. After 5 minutes, the machine goes into JOG mode, then it shuts down,
and either “Way Lube Fault” or “Way Lube Level Low” message will be displayed if the lubrication sys-
tem malfunction is not corrected.
LUBRICATOR REFILL
Check the oil level daily. The oil level can be seen by looking at the sight gage. The lubricator tank
can be refilled at anytime that oil is needed, even while the machine is in operation. If the lubricator is
low on oil, the following conditions exist:
A. “Way Lube Level Low” is displayed and automatic operation is still allowed.
B. When the tank is not refilled within the next 25 minutes, the machine is forced into Block
by Block operation.
C. If the tank is not filled after 5 more minutes, the machine will shut down with the JOG
mode locked on and the “Way Lube Fault” message displayed.
D. When the machine is powered up and the “Way Lube Level Low” message is displayed,
the JOG mode is locked on. Fill the lubricator tank to clear this message and re-enable
the lubrication system.
To fill the lubricator tank:

1. Wipe away any chips, oil, and dirt from
the tank cover.
- NOTE -
Leave the filler tube screen in place.
2. Lift filler cap “A”, Figure 5.2, and fill the
tank with Mobil Vacuoline® #1405 oil.
3. Close the cap and continue with mainte- A
nance or operation.
To correct the low lubricator condition:

1. Fill the lubricator tank.
2. Press the Blank [16] and E-STOP RESET TP2464.
[31] pushbuttons at the same time to re-
move the alarm condition and re-enable Figure 5.2 - Lubricator Filler Cap
the lubrication system.
5-2 M-318A
TRABON® LUBRICATOR RESERVOIR AND
DIVIDER VALVES (FEEDERS)
The TRABON 25-micron filter should be inspected every six months. The filter housing is located
on a bracket just inside the access panel behind the lubricator. Replace the filter unit as necessary. It
is also recommended that the reservoir be cleaned at least once a year. The TRABON lubrication sys-
tem has a master divider valve and feeder valves.
Efficient lubrication, clean valves and feeders, and long bearing life depend on clean lubricant. The
filter cleans the oil before it goes into the lubrication lines and valves.
To change the system filter:

2. Unthread the screws and remove the
lower right end access panel.
3. Unthread plug “B”, Figure 5.3, from the fil-
ter housing. The filter is mounted to the
plug as one unit. Do not remove the filter
from the plug.
4. Thread the replacement plug/filter unit into B
the filter housing. Tighten the plug.
5. If necessary, remove the oil from the tank
and wipe the tank clean with a lint-free
cloth.
6. Lift the filler cap and fill the reservoir with
clean Mobil Vacuoline® #1405 oil. TP2476.
7. Purge the filter housing of air as follows:

Figure 5.3 - Lubrication System Filter
A. Use a hex wrench to unthread the
purge plug on top of the filter housing a few turns.
B. Power up the machine and wait for the pump to cycle several times until lubrication
oil appears around the purge plug threads.
C. Tighten the purge plug.
8. Check the lubrication system for oil leaks. Install the right end access panel.
To prefill and purge (prime) the TRABON lubrication system of air before operation:
Anytime that the lubrication system has air contamination, the air must be purged from the lines and
divider valves. Detailed information to purge the TRABON system is contained in TRABON literature
bulletin 30103.
Master divider valve “C”, Figure 5.4, is mounted on the tray inside the rear access cover. Second-
ary feeders “D”, Figures 5.5, 5.6, and 5.7, are near the ball screw and guideway being lubricated. The
ports in the castings can be located by following the oil lines from the valve or feeders. Each axis being
lubricated has its own secondary feeder.
1. Make certain that the machine is powered down.
Usually this step, along with the doors being open and the covers removed, has been
completed because other components in the system are or have been replaced.
M-318A 5-3
2. Fill the secondary feeder(s) and lubrication
lines as follows:
A. Remove the alternate outlet pipe
plug(s) from the secondary feeder.
B. Connect an oil-filled hand pump to the
outlet opening.
C. Disconnect the lubrication line from its
destination; manually pump the oil while
making certain that oil is filling the line C
and reaching its lubrication point.
To disconnect the lubrication line - push
the line into the fitting; hold the seal
ring in the fitting while wiggling and
pulling the line out of the seal ring.
D. Reconnect the lubrication line at the TP2468.
destination but do not thread in the al-
ternate outlet plugs at this time. Figure 5.4 - Master Divider Valve
Push the line into the seal ring in the
fitting; hold the line in while pulling the D
seal ring as far as it can be pulled out;
tug on the line to set (seal) the line in
the fitting.
E. Repeat steps A through D for all lines
VOGEL
from the secondary feeder to their lubri- Mixing Valve
cation point(s).
3. Next, fill the lubrication lines and master D
valve as follows:
A. Remove the alternate outlet pipe
plug(s) from the master valve.
B. Connect the oil-filled hand pump to the
TP2468.
outlet opening on the master valve.
C. Manually pump oil to fill the lines and Figure 5.5 - Secondary Feeder Valves
purge them of air until oil flows freely from Rear
from the secondary feeder alternate
outlet(s).
D. Re-install the secondary feeder alter-
nate outlet plugs but do not thread in D D
the master valve alternate outlet plug(s)
at this time.
4. Last, fill the master divider valve with oil
using the following procedure:
A. Verify that all alternate outlet pipe
plug(s) have been removed from the
master divider valve.
B. Connect the TRABON® lubrication sys-
tem pump to the inlet of the master di-
vider valve. TP2499.
Figure 5.6 - Secondary Feeders Behind Y2

Axis Casting
5-4 M-318A
C. Turn just the control ON and cycle the
TRABON system pump until oil flows
freely (is discharged) from the master
divider valve alternate outlet opening(s).
D. Thread in the alternate outlet pipe
plug(s) tight on the master divider
valve. Check all other lubrication sys- D
tem fittings to verify that they are tight
and free of leaks.
5. When the lubrication system has been
purged and other work completed, mount
the covers and close the guard doors.
6. Power up the machine. TP2498
Figure 5.7 - Z1 Axis (Collet Closer)

Secondary Feeder
To replace master divider valve “C”, and/or secondary feeders “D”:
If it is ever necessary to replace a valve or feeder section, each has a reference number stamped
on its face; however, Hardinge recommends replacing them as a unit.
Master divider valve sections “C”, are mounted on a manifold while secondary feeder sections “D”,
are mounted together (stacked) between an inlet section and an end section fastened with tie rods. All
sections are sealed by O-rings.
1. Move the axis being worked on to a convenient work position.
3. Open the main door and rear access cover and/or right end access covers. Access to
the Z2 and Y2 secondary feeders may be more convenient through the top.
4. Unthread the screws and remove the way covers or motor covers.
- NOTE -
Check the condition of the O-rings and make certain that an O-ring seals each oil
passageway.
5. On the master divider valve, disconnect the lubrication line(s) only to the section being
replaced; unthread both valve section mounting screws and remove just the valve sec-
tion being replaced.
On the secondary feeder valves, disconnect the lubrication line(s) to the section being
replaced; unthread the tie rod nuts and, being careful of the O-rings, remove the sec-
ondary feeder section(s) to the section being replaced. It may be necessary to unthread
the screws and remove the secondary feeder unit from the mounting location.
6. Verify that the replacement section is the same as the section removed and check the
condition of the O-rings. Replace the O-rings as necessary.
7. Place an O-ring at each oil passageway and mount the new valve either. Tighten the
threads and mount the unit if necessary.
8. Refasten the lubricator line(s). Prefill and purge the lubrication system.
9. Mount the covers and close the guard doors.
10. Power up the machine.
M-318A 5-5
REPLACE THE LUBRICATOR
Replace the lubricator as a unit if any of the lubricator mechanisms such as the motor, pump, or
sensor fail or become damaged. Recycle oil in an environmentally safe manner.
2. Disconnect the oil line from the lubricator.
Push the line into the fitting; hold the seal
ring in the fitting while wiggling and pulling
the line out of the seal ring.
3. Unthread knurled nuts that secure the
grommets which seal the electrical cables.
4. Loosen the screws that fasten the cover to
electrical junction box “E”, Figure 5.8, and
lift off the cover.
5. Make a diagram of the electrical wire con-
nections and connection for the sensor
wire. This will be important to follow when
reconnecting the replacement lubricator.
E
6. Disconnect the wires and remove the ca-
bles from the junction box and fittings.
7. Unthread the nuts that mount the lubrica- TP2464
tor to the bracket. It may be necessary to
unthread the screws on either side of the Figure 5.8 - Lubricator
tank. Replace the lubricator and mount the
new lubricator to the bracket.
8. Feed the cables into the junction box and connect the wires per step #5. Cover the junc-
tion box. Make certain that the grommets are in place and then seal them by tightening
the knurled nuts.
- CAUTION -
Use just enough pipe sealant to secure the fittings. Do not apply sealant to
the first few threads. Excess sealant may be pushed into the lubrication line
and cause it to malfunction.
9. Reconnect the lubrication line to the lubricator. Push the line into the seal ring in the fit-
ting; hold the line in while pulling the seal ring as far as it can be pulled out; tug on the
line to set (seal) the line in the fitting.
10. Power up the machine and check the lubrication flow.
CLEAN THE OIL RESERVOIR

2. Unthread the screws around the lubricator top fastening the reservoir to the top. The lu-
bricator top has all the lubrication mechanisms, suction filter, and reservoir (tank)
mounted to it.
3. Carefully loosen the tank and lower it from the lubricator top. Drain the oil.
4. Wipe the tank clean with a lint-free cloth.
5. Inspect and clean or replace the suction filter on the inlet tube. Check the reservoir gas-
ket and clean or replace it as necessary.
5-6 M-318A
6. Re-align the tank with the lubricator top and fasten it in place with its screws.
7. Lift filler cap “A”, Figure 5.2, and fill the reservoir with clean Mobil Vacuoline® #1405 oil.
8. Power up the machine and check the tank seal for leaks.
CLEAN TRAMP OIL LINE

The lubrication waste oil gravitates into a trough near the center of the z-axis/spline assembly
guideways which drains through the Harcrete base into the tramp oil pan at the right end of the ma-
chine. Recycle oil in an environmentally safe manner.
To clean the tramp oil opening:

1. Jog the turret several inches from Home.
3. Remove and empty the tramp oil pan Fig-
ure 5.9. Place the empty container under
the machine base.
4. Release the two latches and lift the
Z-compartment access door off.
-WARNING -
Always blow the waste oil down
TP2480
through the line into an empty
container. NEVER LOOK into the Figure 5.9 - Tramp Oil Pan
opening while air pressure is
applied.
5. Use an air hose with moderate air pres-
sure to clean waste oil or chips down F
through the opening. A flexible tube may
have to be attached to the nozzle and
shaped to fit under the way cover and into
the waste oil opening.
6. Remove the tramp oil pan and use a
piece of wire up through the oil line if
TP2464.
chips still block the waste oil opening.
Work the wire up through the opening and Figure 5.10 - Tramp Oil Line
push the chips up into the trough.
- CAUTION -
Use a cloth to remove the chips from the trough. Never use an air blast and
do not use bare hands to remove the chips.
7. Wipe the chips from the trough with a rag and put the oil pan under the machine base.
8. Use an air hose with moderate air pressure to clean the waste oil opening again after
using the wire to clear it.
9. Remove the oil pan and clean any debris from it. Replace the pan under the machine.
10. Remount the Z-compartment access door. Fasten both latches to secure the door.
11. Check the oil level in the lubrication reservoir. Fill the reservoir, if necessary, with Mobil
Vacuoline® #1405 oil.
M-318A 5-7
- NOTES -
5-8 M-318A
CHAPTER 6 - MISCELLANEOUS
CONTROL BATTERY UNIT(S)
Each battery unit “A”, Figure 6.1, is located on the front panel of drives in the power case. The con-
trol battery unit supplies power to maintain the control memory when the control is not turned ON. The
unit contains one special lithium battery. Although the batteries should be replaced at least once a
year, there is also a “Battery Low” alarm.
- CAUTION -
Battery replacement can be done with the control turned ON or OFF; how-
ever, the change MUST be done within 30 minutes after the power is OFF. It
is possible that parameters, programs, macros, and offsets will be lost if the
power is OFF and the battery is removed for more than 30 minutes.
Check the age of the battery and replace it as necessary. The number of batteries in any power
case depends on the number of axes and drives.
- NOTES -
The control battery unit supplies power to maintain the control memory when the
control is not turned ON.
Each control unit (drive) contains one lithium battery. Most control battery units are
vertically oriented. Some battery units are located horizontally.
The number of control battery units in the power case is dependent upon the ma-
chine configuration.
To change the battery:

- CAUTION -
A fresh battery must be installed at least once a year. Failure to perform this
maintenance will result in the loss of control information.
1. Make certain that the machine has been powered up.
2. Be sure that the control has been on.
Press the control ON pushbutton if
necessary.
3. Power down the machine or turn the
door interlock key (switch) on the
power case to the OFF position.
A
4. Use the key and unlatch the power A A
case door; open the door.
Pull the tab on the main disconnect
switch down to the right while aligning
the handle and pulling open the door.
5. Remove the battery cover on the front
panel of the power unit, Figure 6.1.
Hold the battery cover by the top and
bottom and squeeze the cover while
pulling it off. TI2466.
(continued on the next page) Figure 6.1 - Control Battery Units
M-318A 6-1
6. Remove the old battery. Pull the connector straight off its pin.
Make certain that the replacement battery is like the battery being removed. Dispose of
the old battery properly.
7. Install the fresh battery. Push the connector on the battery on the pin in the battery unit.
8. Put the battery in place and fasten the battery cover on the front panel.
9. Close the power case door and latch it in both places.
STANDARD SPINDLE COOLING (CHILLER) SYSTEM

The pump is active as soon as the control is turned on and out of E-Stop (emergency stop) condi-
tion. The 7 gallon [26.5 liter] tank contains fluid that is circulated throughout the system. The tank
should be drained, cleaned, and refilled with fresh fluid once a year.
The following maintenance procedures have the
greatest affect on the cooling module’s performance,
efficiency, and life:
A. Maintaining a clean sufficient quantity
of fluid of the proper type and viscosity.
B. Keeping air contamination out of the
system and keeping all connections
leak free.
C. Cleaning the fan and heat exchanger.
The fluid level should be maintained at full or near
full on the sight gauge to ensure good spindle motor
TP3142.
cooling and overall system performance. Power
down the machine to fill the tank. Figure 6.2 - Standard Spindle Cooler
Reservoir
To fill the spindle cooling unit tank:
2. Wipe the filler cap and surrounding area clean of any dirt, debris and contaminants.
3. Twist and lift off the filler cap.
- NOTE -
The automotive anti-freeze ethylene glycol fluid is a 50/50 mix ratio with
deionized/demineralized water.
4. Slowly fill the tank with cooling automotive anti-freeze (ethylene glycol fluid and water
mix). Replace the cap and power up the machine.
- NOTE -
Dispose of the waste cooling fluid in an environmentally safe manner.
To clean and refill the spindle cooler tank:

1. Power down the machine and lock out the main disconnect switch. Pull the tab in the
center of the main disconnect switch out and put a lock through it.
2. Unthread the screws and lift any covers over the cooling module. Twist and lift off the
filler cap.
6-2 M-318A
3. Prepare a shallow pan to drain approximately 7 gallons [26.5 liter] of fluid from the tank.
The pan must be able to fit under the nipple in the lower right corner of the tank and be
next to the platform frame. Refer to Figure 6.2.
4. Unthread the plug from the nipple. Much fluid will drain from the tank at this time.
5. Unthread the screws and carefully lift off the reservoir top. Be careful not to tear the res-
ervoir top gasket.
- NOTE -
Dispose of the waste fluid in an environmentally safe manner.
6. Thoroughly drain the rest of the waste fluid and then wipe the tank.
7. Clean the tank with a solvent recommended by the fluid manufacturer.
8. Wipe the tank clean with a lint free cloth and let air dry.
9. Search for fluid contamination. Eliminate it before adding fresh fluid.
10. Check the filter on the fluid pump intake tube. Clean or replace it as necessary.
11. Make certain that the gasket is in place and mount the reservoir top on the tank. Tighten
the screws.
12. Put pipe sealant or Teflon® tape on the nipple threads; thread the union tightly in place.
- NOTE -
The automotive anti-freeze ethylene glycol fluid is a 50/50 mix ratio with
deionized/demineralized water.
13. Slowly fill the reservoir to the sight gauge Full line (approximately 7 gallons [26.5 liter] of
clean cooling automotive anti-freeze ethylene glycol fluid.
14. Check the reservoir seal and tubes for leaks and add more spindle fluid as necessary.
Mount the access covers in place.
ST216/ST220 HIGH-SPEED SPINDLE MOTOR

COOLING MODULE AND LUBRICATOR
Introduction
The Swiss-Turn 216 and 220 machine high-speed spindle motor has a cooling module and an air
over oil lubrication system. The spindle motor cooling module “B”, Figure 6.3, is located on a platform
at the rear of the machine and is a closed-loop, liquid-circulating, temperature-stabilizing unit for the
spindle motor. The cooling module primarily consists of a reservoir (tank), 1/2-horsepower pump,
stator cooling jacket, flow switch, and a self-contained refrigerant cooling unit. The pump provides 3.2
gallons per minute (gal/min) while the flow switch is activated when the fluid flow is .2 gal/min or less.
The pump is active as soon as the control is turned on. The 7 gallon [26.5 liter] tank contains fluid
that is circulated throughout the system; a pint [.5 liter] of fluid more may be necessary with the refrig-
erant cooling unit. The tank should be drained, cleaned, and refilled with fresh fluid once a year.
The refrigerant cooling unit “C”, sets beside the reservoir and cools the fluid to a pre-set tempera-
ture (thermostat/valve is pinned in place). It has an automatic temperature and its own circulation
pump. It will maintain the fluid temperature in the reservoir regardless of ambient temperature.
M-318A 6-3
The following maintenance procedures have the greatest affect on the cooling module’s perfor-
mance, efficiency, and life:
A. Maintaining a clean sufficient quantity of fluid of the proper type and viscosity.
B. Keeping air contamination out of the system and keeping all connections leak free.
HIGH-SPEED SPINDLE COOLING MODULE

The fluid level should be maintained at full or near full on the sight gauge to ensure good spindle
motor cooling and overall system performance. Read sight gauge tube “D”, Figure 6.3, and fill as nec-
essary; the spindle motor cooling tank has a 7 gallon [26.5 liter] capacity; a pint [.5 liter] of fluid more
may be necessary with the refrigerant cooling unit. Power down the machine to fill the tank.
To fill the spindle motor coolant unit tank: C

2. Wipe the filler cap and surrounding area B
clean of any dirt, debris and contaminants.
3. Twist and lift off the filler cap.
- NOTE -
The automotive anti-freeze ethylene
glycol fluid is a 50/50 mix ratio with
deionized/demineralized water. D
TP2472.
4. Slowly fill the tank with cooling automotive
anti-freeze ethylene glycol fluid. Replace Figure 6.3 - Spindle Motor Cooling Module
the cap and power up the machine. (Cover off the control panel)
- NOTE -
Dispose of the waste cooling fluid in an environmentally safe manner.
To clean and refill the high-speed spindle cooler tank:

Refer to page 6-2, “To clean and refill the spindle cooler tank” to clean the high-speed spindle
cooler tank. This cooler system is the same as the standard spindle cooler tank with the addition of the
refrigerant cooling unit.
REFRIGERANT COOLING UNIT

Information regarding the refrigerant cooling unit “C”, should be supplied by the manufacturer of the
unit and kept with this manual.
6-4 M-318A
HIGH-SPEED SPINDLE AIR/OIL LUBRICATOR (VOGEL)
Check the spindle lubricator oil level once a month. Add Mobil DTE® 797 oil that is prefiltered to 3
mm (Hardinge part number MC -0010912-S), as necessary. The tank should be drained, cleaned,
and refilled with fresh spindle oil once a year. If the oil becomes contaminated, the source of contami-
nation should be eliminated before the tank is refilled. This tank can be filled at any time.
To fill the spindle motor air/oil tank:

1. Wipe the filler cap “E”, Figure 6.4, clean of any dirt, debris, and contaminants.
2. Lift the plastic filler snap cap and slowly fill
the tank with prefiltered Mobil DTE 797 oil.
E
Allow any air in the oil to escape before
powering up the machine. Snap the cap in
place.
To clean and refill the air/oil lubricator tank:

Replace the lubricator as a unit if any of the lubri-
cator mechanisms such as the motor, pump, or sen-
sor fail or become damaged.
- NOTE -
Recycle the oil in an environmentally
safe manner. F

2. Unthread the screws and lift off the electri-
cal junction box cover to gain access to
the lubricator tank screws.
3. Unthread the screws around the lubricator
TP2465.
top fastening the reservoir to the top. The
lubricator top has all the lubrication mech- Figure 6.4 - VOGEL Air/Oil Spindle
anisms, suction filter, and reservoir (tank)
mounted to it. Lubricator
4. Carefully loosen the tank and lower it from the lubricator top. Drain the oil.
5. Wipe the tank clean with a lint-free cloth. Check for contamination and eliminate it be-
fore adding fresh oil.
6. Inspect and clean or replace the suction filter on the inlet tube.
7. Purge air from the unit and lines.
8. Check the reservoir gasket and clean or replace it as necessary.
9. Re-align the tank with the lubricator top and mount it in place with its screws.
10. Lift the plastic filler snap cap and slowly fill the tank with prefiltered Mobil DTE 797 oil.
11. Allow any air in the oil to escape before powering up the machine. Snap the cap in
place.
12. Power up the machine and check for leaks around the reservoir seal and check the lu-
brication flow.
M-318A 6-5
To change the high-speed spindle air/oil lubricator filter:
2. Unthread plug “F”, Figure 6.4, from the filter housing. The filter is mounted to the plug as
one unit. Do not remove the filter from the plug.
3. Thread the replacement plug/filter unit into the filter housing. Tighten the plug.
5. If necessary, remove the oil from the tank and wipe the tank clean with a lint-free cloth.
6. Lift the filler cap and fill the reservoir with clean Mobil DTE® 797 oil that is prefiltered to
3 mm,.
7. Purge the filter and filter housing of air as follows:
A. Use a hex wrench to unthread the line fitting on the filter housing a few turns.
B. Power up the machine and wait for the pump to cycle several times until oil appears
around the fitting.
C. Tighten the fitting.
8. Check the air/oil lubrication system for oil leaks.
To “bleed” the air/oil lubricator mixing block:

The VOGEL mixing block “G”, is located on a bracket at the back of the collet closer. There is no
maintenance to the mixing block; however, it must be “bled” if it is replaced or if air gets into the oil.
1. Power down the machine and lock out the
main disconnect switch. Pull the tab in the
center of the main disconnect switch out
and put a lock through it.
2. Remove the right front access cover. G
3. Unthread, only a turn or two, plug “H”, on
the bottom left of the mixing block.
4. Unlock and power up the machine to
pump some oil through the mixing block. H
Check that the manual switch is ON.
5. Thread in plug “H” tight.
TP2460
6. Replace the right front access cover.
Figure 6.5 - VOGEL Air/Oil Mixing Block
6-6 M-318A
SPINDLE TOGGLES
This information is intended to maintain and adjust the toggles in the main and sub spindles. Main-
tain balance in each spindle by marking and matching each toggle with its slot and so that components
can be re-installed exactly as they have been removed. Keep replacement toggles as a balanced set
and with the same orientation within the set.
- CAUTION -
The life of the spindle toggles depends on proper cleaning and lubrication
as well as the proper toggle force adjustment.
It is recommended to have extra toggle kits as spare parts. The replacement toggle kit for the main
spindle in all machines is Hardinge Part No. SN-0008297-25 and for the sub spindle it is Part No.
SN-0008297-20; each kit contains one set of three toggles.
Clean the toggles and put Klüberpaste® 46MR401 lubrication grease, Hardinge Part No.
MC-0010994-01, on the toggle wear surfaces. The toggle wear surfaces must be lubricated each
month of operation; and, then, every six months the toggles must be removed, cleaned and inspected
for wear, replaced if necessary, lubricated and re-installed. Also, at this time, check the wear on spin-
dle components related to the toggles and replace them as necessary.
Lubricating the toggles

1. Put the control in JOG mode. Remove the
right front access cover to the main spin- Most important lubrication
dle and slide the coolant guard door open wear surface
to gain access to the sub-spindle.

2. Unthread the screws and remove the cov-
ers to gain access to the sub spindle.
3. Use a clean, stiff, nylon or hair bristled
brush to work Klüberpaste 46MR401 in
and on the toggle wear surfaces. Coat the
ends of the toggle and work lubricant into
TP1265.
the slot.
4. Rotate the spindle and lubricate the other Figure 6.6 - Toggle Wear Surfaces
toggles.
5. Open and close the collet several times to
confirm the smooth operation of the toggles.
6. Install the sub spindle cover. Mount the right front access cover and close the coolant
guard door.
Replacing the toggles

1. Remove bar stock from the spindle(s); remove the guide bushing adapter and guide
bushing. Jog the main spindle forward (Z1+); remove the collet cap, collet and collet
adapter.
2. Move the main spindle back (Z1- direction); jog the sub spindle up (Y2+); make certain
that the collet closer for each spindle is open.
Power down the machine.
3. Turn the latches and lift off the right side access covers to the main spindle; slide the
coolant guard door open to gain access to the sub-spindle.
M-318A 6-7
- NOTE - M
Refer to Figures 6.7 and 6.8 for the main O K
spindle and Figure 6.9 for the sub-spindle. P L
4. Unthread the screws and remove the

cover(s) from each spindle. N
5. Unthread the screws and slide way covers
“J”, away from way casting; unthread M J
other screws to remove bar feed bracket
“K”. Q
- NOTES -
R
Replace the toggles in sets only. TP3137.
There is a draw tube (toggle liner) inside Figure 6.7 - Main Spindle
each spindle. It supports the toggles in the
slots in the toggle support.
Note the position of the toggles in the slots in the toggle support and spline.
Make certain that the each toggle is returned to the same slot.
6. Use the following information to clean and replace the main spindle toggles.
A. Loosen three set screws in adjustment nut “L”, and unthread the nut from the spindle.
B. Remove the snap ring from pins “M”, and lift the pins from yoke assembly “N”.
C. Carefully slide the yoke and bearing cone from the spindle. Wipe them clean with
naptha; do not get cleaning solution into the bearings.
D. Unthread three screws and remove toggle support “O”. Wash it clean with naptha.
E. One at a time, lift each toggle from its slot. Clean and reference (mark) its location.
Clean the toggle and slot. Inspect the toggle and components related to the toggles;
replace components as necessary.
F. Remove the draw tube from the spline shaft; clean and inspect the draw tube and i.d.
of the spline shaft where the draw tube pilots (rides). Lubricate the shaft inside diame-
ter (i.d.) with Klüberpaste 46MR401.
G. Also, grease the toggle wear surfaces, slots, and pilot (ground surfaces, ends) of the
draw tube. Put the draw tube into the spline shaft and place the toggles in the slots.
H. Hold the toggles in their slots while sliding toggle support “O”, over the spindle and
toggles until it makes contact with nylon retainer “P”. Align the toggle support screw
holes with the screw holes in the nylon retainer.
Put Loctite© 222 threadlocker on the screw threads; install the screws through the
toggle support and tighten them snug in the nylon.
I. Carefully slide the yoke, with hole “Q”, toward air cylinder shaft “R”, and bearing cone
on the spindle; align the yoke rear mounting hole with the pivot hole and install pin
“M”.
Align the yoke front mounting hole with the air cylinder shaft hole and install the sec-
ond pin “M”. Install a snip ring on each pin.
J. Thread adjustment nut “L”, on until it just makes contact. Do not tighten the adjust-
ment nut or set screws until the toggle force has been set.
K. Mount bar feed bracket “K”, with the hole concentric with the spindle inside diameter
(i.d.); slide way covers “J”, to the bracket and fasten them to it.
6-8 M-318A
Fulcrum
L
S
W
Fulcrum
TP3138.
T
TP3136.
Figure 6.8 - Main Spindle
(Top View) Figure 6.9 - Sub-Spindle
Use the following information to clean and replace the sub spindle toggles.
A. Loosen three set screws in adjustment nut “S”, and unthread it to the left.
B. Remove the far snap ring from pin “T”, and pull the pin from yoke assembly “U”.
C. Use a 5mm ball drive to unthread four screws from sub spindle collet closer bracket
“V”. Remove the bracket and set it near; do not kink the air lines.
D. Unthread three screws and remove yoke holder “W”. Maneuver the yoke assembly
out and rotate it up while removing it.
E. Use a soft-metal rod through the back of the spindle to push the draw tube (thrust
pipe) just far enough to be off the toggles. As the draw tube moves off the toggles,
the toggles pivot one end up out of the slot.
F. One at a time, lift each toggle from its slot. Slide the draw tube out.
Clean the toggle, slot, and draw tube. Inspect the toggle and components related to
the toggles; replace components as necessary, the toggles are replaced as a full set.
G. Grease the toggle wear surfaces (Figure 6.6), slots and draw tube with Klüberpaste
46MR401.
H. Slide the draw tube in and place the toggles in the slots.
M-318A 6-9
- NOTE -
Make certain that the toggle fingers sit in a groove in the toggle sleeve as the draw
tube is pushed back into place.
I. Use a soft metal rod through the front of the spindle to push the draw tube (thrust
pipe) under the toggles until it is seated. Rotate the spindle and check that each of
the toggle fingers are in the groove.
J. Install the yoke assembly in and rotate it down. Mount yoke holder “W”, and tighten
the three screws to 80 inch pounds [9 Nm].
K. Use caution not to kink the air lines while installing sub spindle collet closer bracket
“V”; use the 5mm ball drive and tighten all four screws to 80 inch pounds [9 Nm].
L. Align the yoke mounting holes with the air cylinder shaft hole and install the pin. Make
certain that the snap ring is seated.
M. Thread adjustment nut “S”, on until it just makes contact. Do not tighten the adjust-
ment nut or set screws until the toggle force has been set.
- WARNINGS -
Be extremely careful when working in the machine with the power turned on.
Make certain that all pinch points are clear when operating the chuck
open/close pushbuttons. Also, be sure that the area inside the machine is
clear when moving an axis.
Adjusting the toggle force

2. Install the guide bushing adapter, collet, collet cap, and guide bushing.
3. Make certain that the collet closers are open; have the right side access covers off and
the coolant guard door open; remove the cover(s) from each spindle. The set screws in
adjustment nut “L”, Figure 6.8, and “S”, Figure 6.9, must be loose.
- NOTE -
Adjust the toggle force by threading the adjustment nut as follows:
- Threading the adjustment nut in toward the toggles increases the chucking force.
- Threading the adjustment nut away from the toggles decreases the chucking force.
4. Unthread (loosen) the adjustment nut about one-half turn.

5. Put stock into the spindle(s) being adjusted. The bar stock in the main spindle must
pass through the main collet.
6. Operate the close pushbutton while watching the action of the yoke on the toggles being
adjusted.
6 - 10 M-318A
- NOTE -
Hesitation is the effort the yoke is using to lock the bar stock in the collet. If there
is no hesitation, the bar is not clamped. If the yoke doesn’t move, the adjustment
nut has to be loosened.
Press the MAIN COLLET CLOSE pushbutton.
If the main spindle collet is adjusted properly, the yoke assembly will move and, then,
have a slight hesitation; then, continue moving to the lock position.
Press the SUB CLOSE pushbutton.
If the sub spindle collet is adjusted properly, the yoke assembly will move and, then,
have a slight hesitation; then, continue moving to the lock position.
To tighten the collet grip, thread the adjusting nut in toward the toggles in small incre-
ments. Operate the open/close function several times while watching the yoke action
and confirming the hesitation.
When there is heavy resistance during yoke movement, the collet adjustment is about at
the maximum. If there are collet marks on the stock or part, the collet grip may be too
tight and the adjustment nut must be loosened.
After proper adjustment is achieved, tighten the set screws in the adjustment nut.
7. Operate the collet open/close function several times to open and close the collet and
confirm the toggle force. Make adjustments as necessary to the toggle force.
8. Install the covers over the spindles, mount the right side access covers and close the
coolant guard door before operating the machine.
WORKLIGHT
The worklight is mounted on the headwall on an arm. It is a 20 Watt, 24 Volt OSRAM Halospot 48
halogen lamp (41930 W2, UV-STOP, GY4).
- WARNING -
DO NOT perform any work on electrical components while the electrical
power is ON.
Never touch the glass body of the lamp with bare fingers.
Halogen lamps burn extremely warm. Allow the lamp to cool before han-
dling.
To replace the lamp:

1. Make certain that the cycle has stopped.
Open the coolant guard door.
2. Power down the machine. Wait for the
lamp to cool.
3. Wipe the worklight clean.
4. Grasp the worklight and unthread the lens
retainer ring. Lift off the quad/taper ring
holding the lens in the worklight.
TP2451.
5. Lift (pull) out the lamp.
Figure 6.10 - Worklight
M-318A 6 - 11
6. Unplug the lamp from the wires; make certain that the replacement lamp is the same as
the old lamp; reconnect the new lamp.
- NOTE -
The lens retainer ring should have grease on the threads to seal the threads.
7. Put the lamp up into place and fasten it with its quad/taper ring and thread on the lens
retainer ring.
8. Focus the worklight; close the coolant guard door and power up the machine.
- NOTE -
6 - 12 M-318A
APPENDIX ONE - PREVENTIVE MAINTENANCE
Introduction
To help insure long machine life and keep non-productive downtime to a minimum, perform the
following maintenance after the elapsed times indicated. Maintenance times are approximate.
Components may need attention more frequently if excessive environmental pollution is present.
Preventive maintenance frequency is for single shift and should be increased proportionally when
the machine is run for two or three shifts per day.
Maintaining a clean machine is also part of a preventive maintenance program. The machine
should be wiped with lint-free cloths soaked with Varsol® solvent or equivalent. If the machine is op-
erated in an atmosphere that causes ground and polished surfaces to rust quickly, wipe these sur-
faces with a lint-free cloth soaked in clear mineral oil.
- CAUTION -
Do not use caustic or abrasive cleaners on these machines.
NEVER CLEAN CHIPS FROM THE MACHINE WITH COMPRESSED AIR. Air pressure forces
dirt particles and other foreign matter past the seals and wipers into slides and bearings.
Daily
Drain air line filter . . . . . . . . . . . . . . . . . . . . . . . Chapter 3
Remove chips as necessary and per shift. . . . . . . . . . . . Chapter 4
Check oil level in lubrication reservoir . . . . . . . . . . . . . Chapter 5
Check and adjust toggle lever force on main and sub spindles . . Chapter 6
Check spindle cooler fluid level . . . . . . . . . . . . . . . . Chapter 6
Weekly
Check air filters . . . . . . . . . . . . . . . . . . . . . . . . Chapter 3
Check spindle toggles . . . . . . . . . . . . . . . . . . . . . Chapter 6
Wash machine and wipe down . . . . . . . . . . . . . . . . Introduction above
Check circulating fans for dirt and proper operation . . . . . . . Visual
Monthly
Check and fill air/oil lubricator tank (VOGEL) . . . . . . . . . . Chapter 6
Lubricate toggles in collet closers/drawtube . . . . . . . . . . . Chapter 6
Check power case for contaminants . . . . . . . . . . . . . . Visual
Maintain power case and I/O case door seals . . . . . . . . . . Visual
Half Year
Clean cutting fluid (coolant) reservoir/add fresh coolant . . . . . Chapter 4
Yearly
Control battery unit - install fresh batteries . . . . . . . . . . . Chapter 6
Clean spindle motor cooling module tank . . . . . . . . . . . . Chapter 6
Change spindle motor cooling fluid . . . . . . . . . . . . . . . Chapter 6
M-318A A1 - 1
ADHESIVES AND SEALERS
Loctite No. 592 Pipe Sealant with Teflon . . . . . Loctite Corp.
Loctite No. 242 Threadlocker . . . . . . . . . . . Loctite Corp.
Loctite No. 222 Threadlocker . . . . . . . . . . . Loctite Corp.
Permatex Form-A-Gasket . . . . . . . . . . . . Permatex Co., Inc.
RTV-108 Silicone Rubber Adhesive Sealant . . . . General Electric
RECOMMENDED SPARE PARTS LIST

- NOTE -
Replace spindle toggles in sets (3 pieces) only.
Spindle Toggles:
SN 216/220/225 Toggles
Main Spindle SN-0008297-25
Sub Spindle SN-0008297-20
- NOTES -
A1 - 2 M-318A
APPENDIX TWO - PHOTOGRAPHS
CONQUEST® ST216, CONQUEST ST220, and
CONQUEST ST225 SWISS-TURN LATHE
TP1960A.
Figure A2.1 - Front View
TP2450A. TP3208.
Figure A2.2 - Operator's Control Panels
M-318A A2 - 1
TP2266.
Figure A2.3 - Left Side View
TP2475.
TP3144.
Figure A2.4 - Standard Valve Compartment Figure A2.5 - Valve Compartment with
with Air/Oil Regulator (Before June 1998) One Air Blast Valve (Before June 1998)
A2 - 2 M-318A
TP3145.
Figure A2.6 - Valve Compartment with High-Speed

Spindle Air/Oil Regulator, X- and Z2-Axes Air Blast
(Before June 1998)
TP3146
TP3147
Figure A2.7 - Valve Compartment with Figure A2.8 - Back of Valve Compartment
One Air Blast (June 1998)
M-318A A2 - 3
TP2466.
Figure A2.9 - Power Case Interior
A2 - 4 M-318A
TP3143.
Figure A2.10 - Input/Output (I/O) Case Interior
TP3142.
Figure A2.11 - Standard Spindle Cooler (Chiller) Module
M-318A A2 - 5
Special Air Valve,
Not Standard
TP2470.
Figure A2.12 - Cutting Fluid (Coolant) Pump and

Air/Filter Regulator
Control Cover Removed

Thermostat Set at Factory
and Locked - Do Not
TP2472.
Figure A2.13 - High-Speed Spindle Motor Cooler Module

(Chiller)
A2 - 6 M-318A
TP2452.
Figure A2.14 - Headwall & Tooling Plate
M-318A A2 - 7
TP2453.
Figure A2.15 - Y1 Axis Casting & Ball Screw
A2 - 8 M-318A
TP2459.
Figure A2.16 - Collet Closer with Spindle Orient Option
M-318A A2 - 9
TP2499.
Figure A2.17 - Y2 Axis Secondary Feeders
TP2467.
Figure A2.18 - Rear Access Opening/Coolant Manifold Block
A2 - 10 M-318A
- NOTES -
M-318A A2 - 11
“Performance Has Established Leadership for Hardinge”®
Hardinge Inc.
Elmira, New York 14902-1507 USA
Phone: 607-734-2281 Fax: 607-734-8819
www.hardinge.com

Maintenance Manual: Equipped With The Ge Fanuc 18T Dual Path Control

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MAINTENANCE MANUAL

CONQUEST® ST216, ST220 and ST225

Manual No. M-318A Litho in U.S.A.

Information in this manual is subject to change without notice.

CONVENTIONS USED IN THIS MANUAL

1998, Hardinge Inc. M-318A

HARDINGE SAFETY RECOMMENDATIONS

READ THE APPROPRIATE MANUAL OR INSTRUCTIONS before attempting operation,

CONSULT YOUR SUPERVISOR when in doubt as to the correct way to do a job.

DISCONNECT MAIN ELECTRICAL POWER before attempting repair or maintenance.

ALLOW ONLY AUTHORIZED PERSONNEL to have access to enclosures containing

DON’T ALLOW the operation or repair of equipment by untrained personnel.

KEEP CHEMICAL AND FLAMMABLE MATERIAL away from electrical or operating

DON’T USE a toxic or flammable substance as a solvent cleaner or coolant.

DON’T OPEN GUARD DOORS while any machine component is in motion.

DRY CYCLE a new setup to check for programming errors.

BE CAREFUL of sharp edges when handling newly machined workpieces.

DON’T ADJUST tooling or coolant hoses while the machine is running.

DON’T CHECK finishes or dimensions of workpiece near running spindle or moving

ANY ATTACHMENT, TOOL, OR MACHINE MODIFICATION not obtained from Hardinge

USE ONLY a soft-faced hammer on turret tools and fixtures.

DON’T USE worn or broken tooling on the machine.

DON’T EXCEED the rated capacity of machine.

DON’T LEAVE the machine unattended while it is operating.

DON’T CLEAN the machine with an air hose.

FOR YOUR PROTECTION - WORK SAFELY

CHAPTER 1 - INSTALLATION INSTRUCTIONS

CHAPTER 2 - POWER-UP PROCEDURE

CHAPTER 3 - PNEUMATIC (AIR) FACILITIES

CHAPTER 4 - COOLANT FACILITIES

PLACING THE MACHINE

To set the machine in place:

Figure 1.1 - Swiss-Turn Lathe Footprin

LEVELING THE MACHINE

To level the machine:

Dimensions are English [Metric]

Figure 1.2 - Lag Screw Floor Assembl

CLEANING THE MACHINE

To connect the electrical source:

CUTTING FLUID (COOLANT)

To prepare the coolant system:

ST216/ST220 HIGH-SPEED SPINDLE OPTION

To prepare the motor cooling (chiller) module:

MACHINE POWER-UP PROCEDURE

Figure 2.2 - Operator's Control Panel

COOLANT GUARD DOOR SAFETY INTERLOCK

Figure 3.1 - Air Control Assembly

DRAIN THE FILTER/REGULATOR AND COALESCING FILTER BOWLS

Figure 3.2 - Air Filter Bowls

REPLACE THE AIR CONTROL ASSEMBLY COMPONENTS

(continued on the next page)

REPLACE THE PRESSURE SWITCH

To set the air regulator:

CUTTING FLUIDS (COOLANT)

REMOVING CHIPS AND SHAVINGS

Chip removal procedure:

(continued on the next page)

CLEANING THE RESERVOIR AND FILTERS

To clean the reservoir and filters:

REPLACING THE FLEXIBLE COPPER LINES OR IN-LINE VALVES

To replace an adjustable hose or in-line valve:

Figure 4.1 - Coolant Lines

To clean/replace the tool plate brass ball(s):