MAINTENANCE MANUAL A-0009500-0318.pdf · 2008-01-28 · MAINTENANCE MANUAL CONQUEST ... MAINTENANCE OR REPAIR ON THE SWISS-TURN CNC LATHE. ... Hardinge Inc. recommends that all shop

MAINTENANCE MANUAL

CONQUEST® ST216, ST220 and ST225Swiss-Turn CNC Lathes

Equipped with theGE FANUC 18T DUAL PATH CONTROL

Manual No. M-318A Litho in U.S.A.Part No. M A-0009500-0318 June, 1998

TP1960A

- NOTICE -Damage resulting from misuse, negligence, or accident is not covered by theHardinge 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 theGE Fanuc 18T Dual Path control.

In no event will Hardinge Inc. be responsible for indirect or consequentialdamage resulting from the use or application of the information in thismanual.

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 themachine, tooling, or workpiece.

- NOTES -Notes contain supplemental information.

Hardinge Inc.One Hardinge Drive

P.O. Box 1507Elmira, New York 14902-1507 USA

www.hardinge.com

1998, Hardinge Inc. M-318A

READ ALL OF THESE INSTRUCTIONS CAREFULLY BEFORE STARTINGMAINTENANCE OR REPAIR ON THE SWISS-TURN CNC LATHE.

The technicians who use this manual should have a general knowledge of machine maintenanceand repair. This general knowledge coupled with the following manual will greatly reduce or eliminatedowntime of 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 machinebe 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 chemicalsused with this equipment be supplied to you. A complete list of the chemi-cals used with this machine, their reference data sheet numbers, and theirsuppliers 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 RECOMMENDATIONSYour Hardinge machine is designed and built for maximum ease and safety of operation. However,

some previously accepted shop practices may not reflect current safety regulations and procedures,and should be re-examined to insure compliance with the current safety and health standards.

Hardinge Inc. recommends that all shop supervisors, maintenance personnel, and machine tooloperators be advised of the importance of safe maintenance, setup, and operation of Hardinge-builtequipment. Our recommendations are described 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. Whennecessary, 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 othersafety device.

(continued on the next page)

M-318A i

DON’T OPERATE EQUIPMENT if unusual or excessive heat, noise, smoke, or vibrationoccurs. Report any excessive or unusual vibration, sounds, smoke, or heat as well asany damaged parts.

MAKE CERTAIN equipment is properly grounded. Consult the National Electric Codeand all local codes.

DISCONNECT MAIN ELECTRICAL POWER before attempting repair or maintenance.

ALLOW ONLY AUTHORIZED PERSONNEL to have access to enclosures containingelectrical 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 awet 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 heatersbefore restarting the machine.

KEEP THE AREA AROUND THE MACHINE well lighted and dry.

KEEP CHEMICAL AND FLAMMABLE MATERIAL away from electrical or operatingequipment.

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 closedand 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-holdingdevices 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 workhas been completed by maintenance personnel.

ii M-318A

BEFORE PRESSING THE CYCLE START PUSH BUTTON, make certain that properfunctions 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 operatingthe machine.

INSPECT ALL SAFETY DEVICES AND GUARDS to make certain that they are in goodcondition and are functioning properly before the cycle is started.

CHECK SETUP, TOOLING, AND SECURITY OF WORKPIECE if the machine has beenOFF 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 beforestarting 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 thatall 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 contactwith a moving component of the machine.

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

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 HardingeInc. must be reviewed by a qualified safety engineer before installation.

USE CAUTION around exposed mechanisms and tooling especially when setting up. Becareful 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 jobbeing 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 aworkpiece 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 spindlewithout 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 feedinformation.

MAKE CERTAIN that any bar feed mechanism is properly aligned with the spindle. If thebar feed is a floor-mounted type, it must be securely bolted to floor.

Unless otherwise noted, all operating and maintenance procedures are to be performedby one person. To avoid injury to yourself and others, be sure that all personnel areclear of the machine when opening and closing the coolant guard door and any accesscovers.

FOR YOUR PROTECTION - WORK SAFELY

iv M-318A

- CONTENTS -

CHAPTER 1 - INSTALLATION INSTRUCTIONSPlacing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1Leveling the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4Grounding the Machine . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

Earth Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5System Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6

Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7Pneumatic (Air) Connection . . . . . . . . . . . . . . . . . . . . . . . 1 - 8Lubrication Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8Cutting Fluid (Coolant) . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8ST216/ST220 High Speed Spindle Option Motor Cooling Module . . . . . 1 - 9Non-Metallic Materials Found in Hardinge Machine Construction . . . . . . 1 - 10

CHAPTER 2 - POWER-UP PROCEDUREMachine Power-Up Procedure . . . . . . . . . . . . . . . . . . . . . . 2 - 1Coolant Guard Door Safety Interlock . . . . . . . . . . . . . . . . . . . 2 - 2Power-Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2

CHAPTER 3 - PNEUMATIC (AIR) FACILITIESIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1Air Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2Drain the Filter/Regulator and Coalescing Filter Bowls . . . . . . . . . . 3 - 2Replace the Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3Replace the Air Control Assembly Components. . . . . . . . . . . . . . 3 - 3Replace the Pressure Switch . . . . . . . . . . . . . . . . . . . . . . 3 - 4Air Valve Compartment . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5

CHAPTER 4 - COOLANT FACILITIESIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1Cutting Fluids (Coolant) . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1

Water-Based Coolants . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1Concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2pH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2Water Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2

Coolant Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3Coolant Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3Removing Chips and Shavings . . . . . . . . . . . . . . . . . . . . . 4 - 3Cleaning the Reservoir and Filters . . . . . . . . . . . . . . . . . . . . 4 - 4Replacing the Flexible Copper Lines or In-Line Valves . . . . . . . . . . 4 - 5Tool Plate Coolant Facilities . . . . . . . . . . . . . . . . . . . . . . . 4 - 6Replacing the Coolant Pump . . . . . . . . . . . . . . . . . . . . . . 4 - 6Coolant Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7

M-318A v

CHAPTER 5 - LUBRICATIONIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1Lubrication Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1Lubricator Consumption . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1Lubricator Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2

Fill the Lubricator Tank . . . . . . . . . . . . . . . . . . . . . . . 5 - 2Correct Low Lubricator Condition . . . . . . . . . . . . . . . . . . . 5 - 2

TRABON® Lubricator Reservoir and Divider Valves (Feeders) . . . . . . . 5 - 3Change System Filter . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3Prefill and Purge (Prime) the Lubrication System of Air. . . . . . . . . 5 - 3Replace Master Divider Valve and/or Secondary Feeders . . . . . . . 5 - 5

Replace the Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6Clean the Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6Clean Tramp Oil Line . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7

CHAPTER 6 - MISCELLANEOUSControl Battery Unit(s) . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1Standard Spindle Cooling (Chiller) System . . . . . . . . . . . . . . . . 6 - 2

Fill Spindle Cooling Unit Tank . . . . . . . . . . . . . . . . . . . . 6 - 2Clean and Refill Spindle Cooler Tank . . . . . . . . . . . . . . . . . 6 - 2

ST216/ST220 High-Speed Spindle Cooling Module and Lubricator . . . . . 6 - 3Fill Spindle Motor Coolant Unit Tank . . . . . . . . . . . . . . . . . 6 - 4Clean and Refill High-Speed Spindle Cooler Tank . . . . . . . . . . . 6 - 4Refrigerant Cooling Unit . . . . . . . . . . . . . . . . . . . . . . . 6 - 4Fill Air/Oil Lubricator Tank (VOGEL) . . . . . . . . . . . . . . . . . 6 - 5Clean and Refill the Air/Oil Lubricator Tank . . . . . . . . . . . . . . 6 - 5Change Air/Oil Lubricator Filter . . . . . . . . . . . . . . . . . . . . 6 - 6“Bleed” Air/Oil Lubricator Mixing Block . . . . . . . . . . . . . . . . 6 - 6

Spindle Toggles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7Lubricating the Toggles . . . . . . . . . . . . . . . . . . . . . . . 6 - 7Replacing the Toggles . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7Adjusting the Toggle Force. . . . . . . . . . . . . . . . . . . . . . 6 - 10

Worklight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11

APPENDIX ONEPreventive Maintenance Scheule . . . . . . . . . . . . . . . . . . . . A1 - 1Adhesives and Sealers . . . . . . . . . . . . . . . . . . . . . . . . . A1 - 2Recommended Spare Parts List . . . . . . . . . . . . . . . . . . . . . A1 - 2

APPENDIX TWOPhotographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2

vi M-318A

- NOTES -

M-318A vii

- NOTES -

viii M-318A

CHAPTER 1 - INSTALLATION INSTRUCTIONSCall 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 nocharge, 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 MACHINEThe 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 themachine 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 allthe 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 theway up for clearance.

- NOTES -There are two fork lift slots, 24 inches (609 mm) center to center, running fromfront to rear through the bottom of the machine base. Lift the machine slowly tomake 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 inplace. Remove the bracket and open the door.

M-318A 1 - 1

LEVELING THE MACHINEUnless 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 collectedat 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 otherleveling device is parallel with the spindle centerline. If the machine is ever relocated, it must be totallyre-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 thesame 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 torelease 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 Zaxis linear rail parallel with the spindle centerline.

1 - 2 M-318A

Figure 1.1 - Swiss-Turn Lathe Footprin

87.4[2220.0]

Hold-DownBracket

22.6[574.0]

41.6[1054.1]

26.5[673.1]

0.6[15.2]

Hold-DownBracket

7.7[195.6]

7.8[198.1]

2.1[53.3]

8.5[215.9]

4.5[114.3]

Typ.

66.9[1699.3]

74.5[1892.3]

TI3908.cmx

13

2

4

5

This leg isNOT adjustable.

13.3[337.8]

Spindle Centerline

Tramp-OilPan

- 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 touchthe floor until the machine is level.

Check the height of the coolant tank to be certain that there is clearance with themachine.

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 withthe 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 theholes 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 andmount it as the second bracket on the spindle end. Tighten the screws just enoughto 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

CLEANING THE MACHINE- CAUTION -

Do not use compressed air to clean chips from the machine. Air pressureforces dirt and other foreign matter past the seals and covers into the slides,ball screws, and bearings. This will cause additional wear and will reducethe life and accuracy of the machine.

After the machine has been properly located and leveled, remove all shipping grease, oil, and dirtaccumulated in transit. USE A CLOTH OR BRUSH WITH A GOOD GRADE OF PETROLEUM BASEGREASE 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

Figure 1.2 - Lag Screw Floor Assembl

TI2928.

0.75[19.1]

1.0[25.4]

4.0[29.4]

A. Mark floor at desired locations.B. Drill 0.75 [19.1] hole, 4.0 [29.4] deep.C. Drive expansion shield down to the

bottom of the hole.

Expansion shieldRF-0012120

Concrete Floor

Dimensions are English [Metric]

Hold Down Bracket

WasherCN-0000132

Lag ScrewRF-0012119-04

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 theevent of an electrical fault. To properly ground the machine an Earth Groundand 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 neutralreference wire common to all voltage sources within the system.

Since safety requirements vary with locality, consult local codes which will take precedence overthe 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 conditionsof soil. When installed below permanent moisture level, the impedance of this typeground 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 istypically below 5 OHMS.

3. Other available electrodes, such as metal frames of buildings or metal well castingsmust 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 theequipment 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 insurethat the impedance does not exceed 5 OHMS. The ohmic measurement should be made in terms of avoltage-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 orwelding cable (equivalent to AWG #8 or larger). Braid or welding cable minimizes the resistance athigher frequencies.

When longer lengths are required, use a larger size cable so that the resistance of the cable is lessthan 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 abuseto which it may be exposed.

Interconnect all separate enclosures, control stations, pendant stations, conduits, and the like, toimplement 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 anelectrical fault such as a short circuit. To accomplish this, the grounding setup must assure that allvoltages 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, whichis the system grounding electrode, and a ground clamp. The ground connector used to connect themachine ground block to the electrode must be a braid or welding cable equivalent to AWG #8 orlarger. (Braid or welding cable minimizes the resistance at higher frequencies). When longer lengthsare required, use a larger size cable so that the total resistance of the cable is less than .075 OHMS. Ingeneral, the size must be rated to carry peak short-circuited current of maximum time duration withoutdegrading 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. Ifthe bottom is encountered at a depth of less than four feet, the electrode may be buried horizontally ina 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 localutility 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 supplyhave a supplementary transformer also.

To connect the electrical source:

- WARNING -Make certain that the disconnect switch is in the OFF position when workingin 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 dooropen.

4. Make certain that the line side of discon-nect switch “A”, Figure 1.3, and theground bar inside the case are set to havethe power source and ground line con-nected. If the line side of the disconnectswitch has wire clamps, they must beopen so that the wires can be inserted.

5. Route the power cable into the powercase far enough to easily reach the switchand the ground bar near it. Use a cableclamp to secure the cable at the entranceto the power case. If the line side of thedisconnect switch has screws without wireclamps, fasten a 1/4 inch [6.5 mm] ringclamp to each of the wires.

- CAUTION -Do not apply power to the machine. Start up of the machine is conducted bya Hardinge service engineer.

6. Connect the ground wire and power leads.

The electric power source is connected properly, i.e. phased correctly, when the coolantpump actually circulates coolant upon start up and the spindle chiller (cooling) unit at therear 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

Figure 1.3 - Disconnect Switch

A

TI2466.

PNEUMATIC (AIR) CONNECTIONThe 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 airto the machine goes through the filter/regulator to control the air supply for the machine. A heavy-dutyair dryer may have to be added in the air line if the factory air has excessive moisture. The incoming airline should have a minimum I.D. of 3/8 inch [9.5 mm]; however, if the air line is especially long, a largerinside diameter hose may have to be installed. Connect the air line to the machine. Do not turn the airsource 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 pressuresetting is preferred, however, other applications may require a lower air setting. The air pressureswitch is preset at 60 psi [4.2 bars]. If the pressure falls below this, an alarm message appears on theCRT and the program goes into E-Stop.

LUBRICATION OILThe 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 ensuremaximum 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, itis 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 arecutting oils and water-based coolants.

- CAUTION -Whenever cutting fluids are used, it is essential to follow the manufacturer’srecommendations 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 tosuppress rusting, enhance cutting, increase tool life, promote heat dissipation, and be economical touse.

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 mayresult in rancidity, poor tool life, staining, rusting, foaming, etc., which affect machine performanceand may cause health problems such as dermatitis. Water-based coolants must be correctly specifiedaccording to the machined materials and ensure compatibility with the machine’s components. Referto 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 themachine’s useful life and will minimize corrosion, rusting, staining, etc., and health problems such asdermatitis. 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 ringto 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 intothe chip pan in the coolant reservoir.

4. Pour the coolant directly into the chip pan. Fill the tank with the approved coolant to theFULL (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 ensurethe best performance from the coolant and machine.

ST216/ST220 HIGH-SPEED SPINDLE OPTIONMOTOR 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 rearof the machine.

2. Make the following connections between the machine and cooling module: the coolanthoses to the fittings on the tank by pressing each hose into its fitting. Pull on the hosesto 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 theground 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 coolantand 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 thecooling 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 polycarbonatesneoprene nylonsfluorocarbon rubber phenolic plasticsurethane polyethylenesilicone rubbers PVCcork-nitrile composites PTFE (polytetrafluoroethylene)polyurethane enamelacetal 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 maindisconnect switch near the power casedoor, ON.

- CAUTION -Air filter/regulator bowl “C”, Figure2.2, must be drained at least once aday. If more frequent draining isrequired, it may be necessary toinstall an air dryer in the air line.

2. Open main air lock out valve “B”, Figure2.1, and drain the filter bowl by pressingvalve “C” sideways. Bowl “D”, drains auto-matically.

3. Check lubricant and coolant levels. Addlubricant and coolant as required.

- CAUTION -When pressing CONTROL ON pushbutton “F”, Figure 2.2, DO NOT press anyother CRT/MDI panel pushbuttons or keys until the Position or Alarm screenis displayed. Some pushbuttons and keys have other control maintenance orspecial 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

Figure 2.1 - Machine Air Control Assembly

TP2470A

D

C

A

B

COOLANT GUARD DOOR SAFETY INTERLOCKMachines 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 closedposition. The guard door can be opened when the program cycle is finished.

POWER-DOWN PROCEDURE1. 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

Figure 2.2 - Operator's Control Panel

TI2842

F

E

G

H

TP2450.

I

- NOTES -

M-318A 2 - 3

- NOTES -

2 - 4 M-318A

CHAPTER 3 - PNEUMATIC (AIR) FACILITIESINTRODUCTION

Factory air to the Swiss-Turn lathe goes through a heavy-duty filter/regulator system to set the airpressure and remove contaminants before they get into the machine air supply. A coalescing filter ismounted after the pressure switch manifold to remove additional water vapor and oil. If the factory airhas excessive moisture, a heavy-duty air dryer must be added to the incoming air line. An optional airdrip 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 anair volume requirement of 5 to 6 scfm [142 to 170 lm]; however, if the air line is especially long, a largeri.d. hose may have to be installed. Machines with air operated options may require a higher volume ofair.

Open the main air valve and set the regulator at a consistent pressure from 65 psi to 80 psi [4.5 to5.5 bar]; the upper pressure setting is preferred, however, other applications may require a lower airsetting. The air/oil lubricated machines require an incoming air line pressure of 80 psi [5.5 bar]. The airpressure switch is preset at 60 psi [4.1 bar]. If the pressure falls below this, an alarm message appearson the CRT and the program goes into E-Stop.

POWER-DOWN PROCEDUREWhen 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

Figure 3.1 - Air Control Assembly

TP2470A

AIR CONTROL ASSEMBLYThe 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 blockwith pressure switch, and a coalescing filter. The air system distributes air to: 1) air purge theheadstock or air/oil spindle lubrication, 2) the main air blast which cleans parts and tool tips, 3) operatethe parts catcher, and 4) operate an automatic door. Other regulators and switches are added to thisassembly 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 to170 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 formachines with air/oil spindles.

- WARNING -Do not attempt to block or look into the air port at the bottom of the air lockout 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 -Unless an automatic drainingsystem is used, air filter bowl “B”must be drained at least once a day.If more frequent draining isrequired, it may be necessary toinstall an air dryer on the air line.

Drain the filter/regulator bowl daily by pressing themanual FLEX-DRAIN® petcocks sideways; the co-alescing filter has an automatic drain, however, occa-sionally check its bowl. If a moisture problem exists,add a heavy-duty air dryer to the incoming air line.

3 - 2 M-318A

Figure 3.2 - Air Filter Bowls

BA

TP2470A

C

D

REPLACE THE FILTERSDrain 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 anouter 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 theO-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 AirPressure Low” alarm message from the CRT.

11. Check the air system bowl for contamination, moisture, or air leaks and correct anyproblems as necessary.

REPLACE THE AIR CONTROL ASSEMBLY COMPONENTSAny of the air control assembly components can be replaced if they become damaged. The air con-

trol assembly can also be replaced as a unit.

1. Power down the machine. Make certain that the air lock out valve is OFF.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 railedblocks.

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 thetaper 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 themanifold((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].13. Press the E-STOP RESET pushbutton if it is still necessary to clear “1017 Main Air

Pressure Low” alarm message from the CRT.14. Check the air system bowl for contamination, moisture, or air leaks and correct any

problems as necessary.

REPLACE THE PRESSURE SWITCHPressure 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].

1. Power down the machine. Make certain that the air lock out valve is OFF.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 tothe 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].7. Press the E-STOP RESET pushbutton if it is still necessary to clear “1017 Main Air

Pressure Low” alarm message from the CRT.8. Check the air system bowl for contamination, moisture, or air leaks and correct any

problems as necessary.

3 - 4 M-318A

AIR VALVE COMPARTMENTThe 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 thecompartment. 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 powerup and that the air is turned on with thespindle running at approximately 1000rpm.

2. Unthread the screws and lift off the airvalve compartment access cover at theleft end of the machine.

3. Verify that the main air regulator is set at80 psi [5.5 bar].

4. Pull (lift) regulator knob “E”, Figure 3.3,out. Adjust the air pressure by twisting(turning) the regulator knob until the speci-fied pressure is met while air flowsthrough the system bearings.

5. After the pressure is set, align and pushthe regulator knob in.

6. Mount the air valve compartment accesscover. Continue with maintenance or oper-ation of the machine.

M-318A 3 - 5

Figure 3.3 - Air Valve Compartment

E

TP2475.

Figure 3.4 - Air Panel with X- and Z2-AxesAir Blast Valves

TP3145

Figure 3.5 - Air Valve Compartment SinceJune 1998 w/ One Air Blast Valve

TP3146.

- NOTES -

3 - 6 M-318A

CHAPTER 4 - COOLANT FACILITIESINTRODUCTION

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 theheadwall, 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 tankthrough the chip pan.

Clean the pan of chips and then pour the coolant directly into the pan. Fill the coolant reservoir withthe 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 bypressing the COOLANT pushbutton. The opposite is also true. If coolant is not programmed and it isneeded, coolant can be activated by pressing the COOLANT pushbutton. If coolant flow has not beenactivated by the program, pressing COOLANT will start coolant flow even though an M08, M13, orM14 has not been programmed. However, if the program is repeated, the pushbutton must bepressed 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 theworkpiece and tool tips. Liquid flow to the nozzle is controlled by the COOLANT control pushbutton orby 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, itis impossible to test material compatibility with each and every coolant. The two most popular types ofcutting fluids are cutting oils and water-based coolants.

- CAUTION -Whenever cutting fluids are used, it is essential to follow the manufacturer’srecommendations 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 tosuppress rusting, enhance cutting, increase tool life, promote heat dissipation, and be economical touse.

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 mayresult in rancidity, poor tool life, staining, rusting, foaming, etc., which affect machine performanceand may cause health problems such as dermatitis. Water-based coolants must be correctly specifiedaccording to the machined materials and ensure compatibility with the machine’s components. Referto 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 increasethe 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 andcorrection of coolant concentration, a measure of coolant pH, and removal of any tramp oil from themachine 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. Aconversion factor or chart, which may vary from coolant to coolant and is suppliedby the coolant manufacturer, may be required to convert the refractometer readingto 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 conditionswhich tends to increase the coolant concentration over a normal work shift. The coolant concentrationmust 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 otherproblems. Rich concentrations can result in foam, residues, health problems such as dermatitis, andincreased 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. ThepH 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 andlongevity. 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 theformation of a soap like scum which adheres to sumps, filters, etc. It is best to consult with your coolantmanufacturer representative to determine your requirements.

- NOTE -A properly selected and maintained cutting fluid, either cutting oil or water-basedcoolant, will ensure the best performance from the cutting fluid and the machine.

4 - 2 M-318A

COOLANT TANKThe 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 bedrained 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 thecoolant tank to fill the coolant tank. Either water-based or oil-based coolant may be used.

COOLANT LINESCoolant 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 oneach 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 detailedprocedure 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.3. Press EMERGENCY STOP pushbutton.4. Press CONTROL OFF pushbutton.5. Turn main air lock out valve OFF.6. Turn main disconnect switch OFF.

REMOVING CHIPS AND SHAVINGSThe 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 fromthe chip pan. Injury may result from attempting to remove chips without arake. 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 thechip pan. Make adjustments before powering up the machine and turning the coolant on.

CLEANING THE RESERVOIR AND FILTERSClean 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:

1. Power down the machine.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 fromthe chip pan. Injury may result from attempting to remove chips without arake. 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 pipeplug 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, andshavings 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 inplace 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 thechip 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 tothe 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 VALVESFlexible 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 coppertubes or cut the tubing.

To replace an adjustable hose or in-line valve:

1. Power down the machine.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 tubingand thread the copper line into the valve.Use pipe sealant on the fitting threadswhen replacing either the valves or copperlines.

5. Adjust the length and angle of the coppertubing for the best coolant direction.

6. Power up the machine and adjust thecoolant flow as necessary.

M-318A 4 - 5

Figure 4.1 - Coolant Lines

A

TP2274.

TOOL PLATE COOLANT FACILITIESEach 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 toolplate 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 alteredto fit specific needs.

2. Carefully unthread the brass ball mounting screw. Be prepared to catch the screw andbrass ball from the tool plate.

3. Wipe clean the brass ball or replace it. Wipe each part dry with a lint free cloth andcheck 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 PUMPThe 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 andtool plate openings.

1. Power down the machine.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 coolanthose from the fitting on the tank.

4. Unthread the four bolts and remove theflat washers and lock washers to loosenthe coolant pump from the shelf.

5. Unthread the screws to the electrical junc-tion box cover on the pump and remove itto gain entrance to the wires.

6. Make a diagram of the electrical wire con-nections. This diagram will be important tofollow when connecting the replacementpump.

7. Disconnect the wires and remove the leadcable from the junction box.

8. Remove the coolant pump from the shelf.

- NOTE -Do not cut the hoses unless the fittings do not turn when the hose clamps areloosened. 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 andmounted on the new pump.

4 - 6 M-318A

Figure 4.2 - Coolant Pump

TP2470.

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 VALVESThe 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 byelectrical solenoid valves in the air valve compartment at the left end of the machine.

The coolant valves or the plug where the optionalback tool slide would be are as follows:

A. HeadwallB. Back tool slideC. Tool plate

The coolant comes directly from the coolant pumpthrough hose “D”, into the valve manifold.

There is no maintenance to the control valves;however, if they become damaged, replace them asa unit. Power down the machine and wait a minute forcoolant pressure to subside while unthreading thescrews and lifting off the rear access cover. Loosenthe 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 controlvalve. Thread in the air hose fitting and reconnect the air hose; thread in the coolant hose connectionand 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

Figure 4.3 - Coolant Solenoid Valves

A

B

C

TP2467.

D

- NOTES -

4 - 8 M-318A

CHAPTER 5 - LUBRICATIONINTRODUCTION

Lubrication is accomplished through a Lubriquip Inc. TRABON® progressive distribution system forthe 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 andonly has periodic cycles during other modes. Whenthe lubrication system requires maintenance, themachine 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 arestationary.

3. Press EMERGENCY STOP pushbutton.4. Press CONTROL OFF pushbutton.5. Turn main air lock out valve OFF.6. Turn main disconnect switch OFF.

LUBRICATION OILThe 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 areafor 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 thatall times are approximate and that variations on an individual machine could be up to ±10% from thetime listed. If actual lubrication consumption is greater or less than the acceptable range given, checkthe 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) oilwhen 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 machinesoftware and is preset at Hardinge.

M-318A 5 - 1

Figure 5.1 - Lubricator

TP2464

The machine software detects the following information:

A. Pump malfunctionB. Defective cycle switchC. Plugged main linesD. Broken master block oil supply line.

If the cycle software senses a failure in the lubrication system, a “Way Lube Fault, 5 Minutes toShutdown” message will be displayed and setup mode (Block by Block) is activated to allow the tool tobe 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 REFILLCheck 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 islow 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-enablethe lubrication system.

To fill the lubricator tank:

1. Wipe away any chips, oil, and dirt fromthe tank cover.

- NOTE -Leave the filler tube screen in place.

2. Lift filler cap “A”, Figure 5.2, and fill thetank with Mobil Vacuoline® #1405 oil.

3. Close the cap and continue with mainte-nance or operation.

To correct the low lubricator condition:

1. Fill the lubricator tank.2. Press the Blank [16] and E-STOP RESET

[31] pushbuttons at the same time to re-move the alarm condition and re-enablethe lubrication system.

5 - 2 M-318A

Figure 5.2 - Lubricator Filler CapTP2464.

A

TRABON® LUBRICATOR RESERVOIR ANDDIVIDER VALVES (FEEDERS)

The TRABON 25-micron filter should be inspected every six months. The filter housing is locatedon a bracket just inside the access panel behind the lubricator. Replace the filter unit as necessary. Itis 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. Thefilter cleans the oil before it goes into the lubrication lines and valves.

To change the system filter:

1. Power down the machine.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 theplug as one unit. Do not remove the filterfrom the plug.

4. Thread the replacement plug/filter unit intothe filter housing. Tighten the plug.

5. If necessary, remove the oil from the tankand wipe the tank clean with a lint-freecloth.

6. Lift the filler cap and fill the reservoir withclean Mobil Vacuoline® #1405 oil.

7. Purge the filter housing of air as follows: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 anddivider valves. Detailed information to purge the TRABON system is contained in TRABON literaturebulletin 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. Theports in the castings can be located by following the oil lines from the valve or feeders. Each axis beinglubricated 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 beencompleted because other components in the system are or have been replaced.


M-318A 5 - 3

Figure 5.3 - Lubrication System Filter

B

TP2476.

2. Fill the secondary feeder(s) and lubricationlines 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 whilemaking certain that oil is filling the lineand reaching its lubrication point.To disconnect the lubrication line - pushthe line into the fitting; hold the sealring in the fitting while wiggling andpulling the line out of the seal ring.

D. Reconnect the lubrication line at thedestination but do not thread in the al-ternate outlet plugs at this time.Push the line into the seal ring in thefitting; hold the line in while pulling theseal ring as far as it can be pulled out;tug on the line to set (seal) the line inthe fitting.

E. Repeat steps A through D for all linesfrom the secondary feeder to their lubri-cation point(s).

3. Next, fill the lubrication lines and mastervalve as follows:A. Remove the alternate outlet pipe

plug(s) from the master valve.B. Connect the oil-filled hand pump to the

outlet opening on the master valve.C. Manually pump oil to fill the lines and

purge them of air until oil flows freelyfrom the secondary feeder alternateoutlet(s).

D. Re-install the secondary feeder alter-nate outlet plugs but do not thread inthe master valve alternate outlet plug(s)at this time.

4. Last, fill the master divider valve with oilusing the following procedure:A. Verify that all alternate outlet pipe

plug(s) have been removed from themaster divider valve.

B. Connect the TRABON® lubrication sys-tem pump to the inlet of the master di-vider valve.

5 - 4 M-318A

Figure 5.4 - Master Divider Valve

C

TP2468.

Figure 5.5 - Secondary Feeder Valvesfrom Rear

D

VOGELMixing Valve

D

TP2468.

Figure 5.6 - Secondary Feeders Behind Y2Axis Casting

D D

TP2499.

C. Turn just the control ON and cycle theTRABON system pump until oil flowsfreely (is discharged) from the masterdivider valve alternate outlet opening(s).

D. Thread in the alternate outlet pipeplug(s) tight on the master dividervalve. Check all other lubrication sys-tem fittings to verify that they are tightand free of leaks.

5. When the lubrication system has beenpurged and other work completed, mountthe covers and close the guard doors.

6. Power up the machine.

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 stampedon 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. Allsections are sealed by O-rings.

1. Move the axis being worked on to a convenient work position.2. Power down the machine.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 oilpassageway.

5. On the master divider valve, disconnect the lubrication line(s) only to the section beingreplaced; 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 beingreplaced; 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 unthreadthe 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 thecondition 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 thethreads 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.


M-318A 5 - 5

Figure 5.7 - Z1 Axis (Collet Closer)Secondary Feeder

D

TP2498

REPLACE THE LUBRICATORReplace 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.

1. Power down the machine.2. Disconnect the oil line from the lubricator.

Push the line into the fitting; hold the sealring in the fitting while wiggling and pullingthe line out of the seal ring.

3. Unthread knurled nuts that secure thegrommets which seal the electrical cables.

4. Loosen the screws that fasten the cover toelectrical junction box “E”, Figure 5.8, andlift off the cover.

5. Make a diagram of the electrical wire con-nections and connection for the sensorwire. This will be important to follow whenreconnecting the replacement lubricator.

6. Disconnect the wires and remove the ca-bles from the junction box and fittings.

7. Unthread the nuts that mount the lubrica-tor to the bracket. It may be necessary tounthread the screws on either side of thetank. Replace the lubricator and mount thenew 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 tighteningthe knurled nuts.

- CAUTION -Use just enough pipe sealant to secure the fittings. Do not apply sealant tothe first few threads. Excess sealant may be pushed into the lubrication lineand 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 theline to set (seal) the line in the fitting.

10. Power up the machine and check the lubrication flow.

CLEAN THE OIL RESERVOIR1. Power down the machine.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

Figure 5.8 - Lubricator

TP2464

E

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 LINEThe 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.2. Power down the machine.3. Remove and empty the tramp oil pan Fig-

ure 5.9. Place the empty container underthe machine base.

4. Release the two latches and lift theZ-compartment access door off.

-WARNING -Always blow the waste oil downthrough the line into an emptycontainer. NEVER LOOK into theopening while air pressure isapplied.

5. Use an air hose with moderate air pres-sure to clean waste oil or chips downthrough the opening. A flexible tube mayhave to be attached to the nozzle andshaped to fit under the way cover and intothe waste oil opening.

6. Remove the tramp oil pan and use apiece of wire up through the oil line ifchips still block the waste oil opening.Work the wire up through the opening andpush the chips up into the trough.

- CAUTION -Use a cloth to remove the chips from the trough. Never use an air blast anddo 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.12. Power up the machine.

M-318A 5 - 7

Figure 5.9 - Tramp Oil Pan

TP2480

Figure 5.10 - Tramp Oil Line

TP2464.

F

- NOTES -

5 - 8 M-318A

CHAPTER 6 - MISCELLANEOUSCONTROL 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. Theunit contains one special lithium battery. Although the batteries should be replaced at least once ayear, 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. Itis possible that parameters, programs, macros, and offsets will be lost if thepower 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 powercase depends on the number of axes and drives.

- NOTES -The control battery unit supplies power to maintain the control memory when thecontrol is not turned ON.Each control unit (drive) contains one lithium battery. Most control battery units arevertically 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 thismaintenance 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 ifnecessary.

3. Power down the machine or turn thedoor interlock key (switch) on thepower case to the OFF position.

4. Use the key and unlatch the powercase door; open the door.Pull the tab on the main disconnectswitch down to the right while aligningthe handle and pulling open the door.

5. Remove the battery cover on the frontpanel of the power unit, Figure 6.1.Hold the battery cover by the top andbottom and squeeze the cover whilepulling it off.


M-318A 6 - 1

Figure 6.1 - Control Battery Units

TI2466.

AA A

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 ofthe 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) SYSTEMThe 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 tankshould be drained, cleaned, and refilled with fresh fluid once a year.

The following maintenance procedures have thegreatest affect on the cooling module’s performance,efficiency, and life:

A. Maintaining a clean sufficient quantityof fluid of the proper type and viscosity.

B. Keeping air contamination out of thesystem and keeping all connectionsleak 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 motorcooling and overall system performance. Powerdown the machine to fill the tank.

To fill the spindle cooling unit tank:

1. Power down the machine.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 withdeionized/demineralized water.

4. Slowly fill the tank with cooling automotive anti-freeze (ethylene glycol fluid and watermix). 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 thecenter 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 thefiller cap.

6 - 2 M-318A

Figure 6.2 - Standard Spindle CoolerReservoir

TP3142.

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 benext 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 withdeionized/demineralized water.

13. Slowly fill the reservoir to the sight gauge Full line (approximately 7 gallons [26.5 liter] ofclean 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 MOTORCOOLING MODULE AND LUBRICATOR

IntroductionThe 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 platformat the rear of the machine and is a closed-loop, liquid-circulating, temperature-stabilizing unit for thespindle 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 3.2gallons 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 fluidthat 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 circulationpump. 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 MODULEThe 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 moremay be necessary with the refrigerant cooling unit. Power down the machine to fill the tank.

To fill the spindle motor coolant unit tank:

1. Power down the machine.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 ethyleneglycol fluid is a 50/50 mix ratio withdeionized/demineralized water.

4. Slowly fill the tank with cooling automotiveanti-freeze ethylene glycol fluid. Replacethe cap and power up the machine.

- 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 spindlecooler tank. This cooler system is the same as the standard spindle cooler tank with the addition of therefrigerant cooling unit.

REFRIGERANT COOLING UNITInformation regarding the refrigerant cooling unit “C”, should be supplied by the manufacturer of the

unit and kept with this manual.

6 - 4 M-318A

Figure 6.3 - Spindle Motor Cooling Module(Cover off the control panel)

C

B

TP2472.

D

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.Allow any air in the oil to escape beforepowering up the machine. Snap the cap inplace.

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 environmentallysafe manner.

1. Power down the machine.2. Unthread the screws and lift off the electri-

cal junction box cover to gain access tothe lubricator tank screws.

3. Unthread the screws around the lubricatortop fastening the reservoir to the top. Thelubricator top has all the lubrication mech-anisms, suction filter, and reservoir (tank)mounted to it.

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

Figure 6.4 - VOGEL Air/Oil SpindleLubricator

E

TP2465.

F

To change the high-speed spindle air/oil lubricator filter:

1. Power down the machine.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 nomaintenance 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 themain disconnect switch. Pull the tab in thecenter of the main disconnect switch outand put a lock through it.

2. Remove the right front access cover.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.Check that the manual switch is ON.

5. Thread in plug “H” tight.6. Replace the right front access cover.

6 - 6 M-318A

Figure 6.5 - VOGEL Air/Oil Mixing Block

H

G

TP2460

SPINDLE TOGGLESThis 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 componentscan be re-installed exactly as they have been removed. Keep replacement toggles as a balanced setand with the same orientation within the set.

- CAUTION -The life of the spindle toggles depends on proper cleaning and lubricationas well as the proper toggle force adjustment.

It is recommended to have extra toggle kits as spare parts. The replacement toggle kit for the mainspindle 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 eachmonth of operation; and, then, every six months the toggles must be removed, cleaned and inspectedfor 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 theright front access cover to the main spin-dle and slide the coolant guard door opento 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 bristledbrush to work Klüberpaste 46MR401 inand on the toggle wear surfaces. Coat theends of the toggle and work lubricant intothe slot.

4. Rotate the spindle and lubricate the othertoggles.

5. Open and close the collet several times toconfirm the smooth operation of the toggles.

6. Install the sub spindle cover. Mount the right front access cover and close the coolantguard door.

Replacing the toggles

1. Remove bar stock from the spindle(s); remove the guide bushing adapter and guidebushing. Jog the main spindle forward (Z1+); remove the collet cap, collet and colletadapter.

2. Move the main spindle back (Z1- direction); jog the sub spindle up (Y2+); make certainthat 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 thecoolant guard door open to gain access to the sub-spindle.


M-318A 6 - 7

Figure 6.6 - Toggle Wear Surfaces

TP1265.

Most important lubricationwear surface

- NOTE -Refer to Figures 6.7 and 6.8 for the mainspindle and Figure 6.9 for the sub-spindle.

4. Unthread the screws and remove thecover(s) from each spindle.

5. Unthread the screws and slide way covers“J”, away from way casting; unthreadother screws to remove bar feed bracket“K”.

- NOTES -Replace the toggles in sets only.There is a draw tube (toggle liner) insideeach spindle. It supports the toggles in theslots 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 thedraw 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 andtoggles until it makes contact with nylon retainer “P”. Align the toggle support screwholes with the screw holes in the nylon retainer.Put Loctite© 222 threadlocker on the screw threads; install the screws through thetoggle support and tighten them snug in the nylon.

I. Carefully slide the yoke, with hole “Q”, toward air cylinder shaft “R”, and bearing coneon 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

Figure 6.7 - Main Spindle

K

J

TP3137.

M

L

Q

R

OP

N

M

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 tothe 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 Klüberpaste46MR401.

H. Slide the draw tube in and place the toggles in the slots.


M-318A 6 - 9

Figure 6.8 - Main Spindle(Top View)

L

TP3138.

Fulcrum

Figure 6.9 - Sub-Spindle

S

Fulcrum

TTP3136.

V

U

W

- NOTE -Make certain that the toggle fingers sit in a groove in the toggle sleeve as the drawtube is pushed back into place.

I. Use a soft metal rod through the front of the spindle to push the draw tube (thrustpipe) under the toggles until it is seated. Rotate the spindle and check that each ofthe toggle fingers are in the groove.

J. Install the yoke assembly in and rotate it down. Mount yoke holder “W”, and tightenthe 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. Makecertain 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 chuckopen/close pushbuttons. Also, be sure that the area inside the machine isclear when moving an axis.

Adjusting the toggle force

1. Power up the machine.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 inadjustment 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 thereis no hesitation, the bar is not clamped. If the yoke doesn’t move, the adjustmentnut 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 actionand confirming the hesitation.

When there is heavy resistance during yoke movement, the collet adjustment is about atthe maximum. If there are collet marks on the stock or part, the collet grip may be tootight 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 andconfirm 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 thecoolant guard door before operating the machine.

WORKLIGHTThe 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 electricalpower 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 thelamp to cool.

3. Wipe the worklight clean.4. Grasp the worklight and unthread the lens

retainer ring. Lift off the quad/taper ringholding the lens in the worklight.

5. Lift (pull) out the lamp.

M-318A 6 - 11

Figure 6.10 - Worklight

TP2451.

6. Unplug the lamp from the wires; make certain that the replacement lamp is the same asthe 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 lensretainer ring.

8. Focus the worklight; close the coolant guard door and power up the machine.

- NOTE -

6 - 12 M-318A

APPENDIX ONE - PREVENTIVE MAINTENANCEIntroduction

To help insure long machine life and keep non-productive downtime to a minimum, perform thefollowing 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 whenthe machine is run for two or three shifts per day.

Maintaining a clean machine is also part of a preventive maintenance program. The machineshould 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 forcesdirt particles and other foreign matter past the seals and wipers into slides and bearings.

DailyDrain air line filter . . . . . . . . . . . . . . . . . . . . . . . Chapter 3Remove chips as necessary and per shift. . . . . . . . . . . . Chapter 4Check oil level in lubrication reservoir . . . . . . . . . . . . . Chapter 5Check and adjust toggle lever force on main and sub spindles . . Chapter 6Check spindle cooler fluid level . . . . . . . . . . . . . . . . Chapter 6

WeeklyCheck air filters . . . . . . . . . . . . . . . . . . . . . . . . Chapter 3Check spindle toggles . . . . . . . . . . . . . . . . . . . . . Chapter 6Wash machine and wipe down . . . . . . . . . . . . . . . . Introduction aboveCheck circulating fans for dirt and proper operation . . . . . . . Visual

MonthlyCheck and fill air/oil lubricator tank (VOGEL) . . . . . . . . . . Chapter 6Lubricate toggles in collet closers/drawtube . . . . . . . . . . . Chapter 6Check power case for contaminants . . . . . . . . . . . . . . VisualMaintain power case and I/O case door seals . . . . . . . . . . Visual

Half YearClean cutting fluid (coolant) reservoir/add fresh coolant . . . . . Chapter 4

YearlyControl battery unit - install fresh batteries . . . . . . . . . . . Chapter 6Clean spindle motor cooling module tank . . . . . . . . . . . . Chapter 6Change spindle motor cooling fluid . . . . . . . . . . . . . . . Chapter 6

M-318A A1 - 1

ADHESIVES AND SEALERSLoctite 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 - PHOTOGRAPHSCONQUEST® ST216, CONQUEST ST220, and

CONQUEST ST225 SWISS-TURN LATHE

M-318A A2 - 1

Figure A2.1 - Front View

TP1960A.

Figure A2.2 - Operator's Control Panels

TP2450A. TP3208.

A2 - 2 M-318A

Figure A2.3 - Left Side View

TP2266.

Figure A2.4 - Standard Valve Compartmentwith Air/Oil Regulator (Before June 1998)

TP2475.

Figure A2.5 - Valve Compartment withOne Air Blast Valve (Before June 1998)

TP3144.

M-318A A2 - 3

Figure A2.6 - Valve Compartment with High-SpeedSpindle Air/Oil Regulator, X- and Z2-Axes Air Blast

(Before June 1998)

TP3145.

Figure A2.7 - Valve Compartment withOne Air Blast (June 1998)

TP3146

Figure A2.8 - Back of Valve Compartment

TP3147

A2 - 4 M-318A

Figure A2.9 - Power Case Interior

TP2466.

M-318A A2 - 5

Figure A2.10 - Input/Output (I/O) Case Interior

TP3143.

Figure A2.11 - Standard Spindle Cooler (Chiller) Module

TP3142.

A2 - 6 M-318A

Figure A2.12 - Cutting Fluid (Coolant) Pump andAir/Filter Regulator

TP2470.

Special Air Valve,Not Standard

Figure A2.13 - High-Speed Spindle Motor Cooler Module(Chiller)

TP2472.

Control Cover RemovedThermostat Set at Factoryand Locked - Do Not

M-318A A2 - 7

Figure A2.14 - Headwall & Tooling Plate

TP2452.

A2 - 8 M-318A

Figure A2.15 - Y1 Axis Casting & Ball Screw

TP2453.

M-318A A2 - 9

Figure A2.16 - Collet Closer with Spindle Orient Option

TP2459.

A2 - 10 M-318A

Figure A2.17 - Y2 Axis Secondary Feeders

TP2499.

Figure A2.18 - Rear Access Opening/Coolant Manifold Block

TP2467.

- NOTES -

M-318A A2 - 11

“Performance Has Established Leadership for Hardinge”®

Hardinge Inc.Elmira, New York 14902-1507 USA

Phone: 607-734-2281 Fax: 607-734-8819www.hardinge.com

Documents

MAINTENANCE MANUAL A-0009500-0318.pdf · 2008-01-28 · MAINTENANCE MANUAL CONQUEST ... MAINTENANCE OR REPAIR ON THE SWISS-TURN CNC LATHE. ... Hardinge Inc. recommends that all shop