Attachment 4 - Current Machine Manual and Drawings.pdf

CINCINNATI GILBERT

Series D Floor Type

HORIZONTAL BORING MACHINE

TABLE OF CONTENTS

Section I --- INTRODUCTION AND DESCRIPTION

1.4 GENERAL DESCRIPTION

1.5 MAJOR MACHINE COMPONENTS

1.6 AUXILIARY COMPONENTS

1.7 IDENTIFICATION AND DATA PLATES

1.8 RELATED PUBLICATIONS

Section II --- UNPACKING, INSTALLATION AND PREPARATION FOR

OPERATION

2.1 GENERAL

2.2 SPECIAL TOOLS

2.3 CUSTOMER FURNISHED MATERIALS FOR INSTALLATION

2.4 DISASSEMBLY PRIOR TO SHIPMENT

2.5 RECEIVING INSPECTION

2.6 FOUNDATION REQUIREMENTS

2.7 INSTALLATION SAFETY PRECAUTIONS

2.8 INSTALLATION PRECAURIONS

2.9 GENERAL INSTALLATION PROCEDURES

2.10 DETAILED INSTALLATION PROCEDURES

2.11 LEVEL AND ALIGNMENT CHECK

Section III --- OPERATING INSTRUCTIONS

3.1 GENERAL

3.2 OPERATING CONTROLS

3.3 OPERATING NOTES

Section IV --- PERIODIC MAINTENANCE

4.1 GENERAL

4.2 PERIODIC INSPECTIONS

4.3 LUBRICATION

4.4 PERIODIC INSPECTION AND LUBRICATION NOTES

Section V --- GENERAL MAINTENANCE

5.1 GENERAL

5.2 HYDRAULIC SYSTEM

5.3 ELECTRICAL TROUBLESHOOTING NOTES

5.4 TROUBLESHOOTING

5.5 LIMIT SWITCH ADJUSTMENT

5.6 LINEAR ENCODER FEEDBACK SYSTEM

Section VI --- REPAIR PARTS

PREFACE

IMPORTANT

Carefully read the instructions and safety precautions in this manual. Do not attempt to operate the tool changer and tool storage units until you have read the manual thoroughly and understand the instructions.

At the time of this writing, the manual was completely up to date. However, due to continual improvements in design, it is possible some instructions and descriptions contained in the manual may vary to a slight extend from the machine delivered to you. This merely implies that the machine has been improved to better fulfill your requirements. If there are any questions, you are encouraged to contact The Cincinnati Gilbert Machine Tool Company, LLC for clarification.

NOTE: The general Safety Precautions (pages S-1 thru S-15) are supplemented by specific safety WARNINGS throughout the manual.

THE CINCINNATI GILBERT MACHINE TOOL COMPANY, LLC

3366 BEEKMAN STREET

CINCINNATI, OHIO 45223 U.S.A.

PHONE: 513-541-4815

FAX: 513-541-4885

S-1

SAFETY PRECAUTIONS

IMPORTANT:

These safety precautions for this CINCINNATI GILBERT MACHINE TOOL have been prepared to assist the operator and maintenance personnel in the performance of good shop safety procedures in general.

Operator and maintenance personnel should read and understand these precautions completely before operating, setting up, running or performing maintenance on the machine. Failure to comply with instructions may result in serious injury. These precautions are to be used as a guide to supplement the following:

a. All other manuals pertaining to the machine.

b. Local, plant and shop safety rules and codes.

c. Federal and national safety laws and regulations.

NOTE: Emphasis should be placed on information set forth in the latest edition of the OCCUPATIONAL SAFETY AND HEALTH STANDARDS which is available from the DEPARTMENT OF LABOR, WASHINGTON, ❑.C. These standards contain the present occupational safety and health standards set forth by Federal regulations.

S-2

PERSONAL SAFETY:

Remember, machines do not cause accidents, injuries or death. People do!

Careless . . . over-confident people. THINK . . . ACT Safety.

Know and respect your machinery. Read and practice the prescribed safety and checking procedures. Make sure that everyone who works for, with or near you fully understands - and more importantly - follows these safety precautions and procedures when operating machines.

Always be mentally alert on the job and keep in good physical condition. A person who is not alert can injure himself.

Avoid sudden movements, loud noises, etc., which can distract others who are working near you.

Be alert to conditions in your working area and throughout the plant. Observe "No Smoking", "High Voltage" and other warnings.

Accidents can occur that result in serious personal injury to yourself or others due to clothing and other articles becoming entangled in cutters, handwheels, levers or moving machine elements. The following suggestions, if followed, will help you avoid such accidents: Neckties, scarves, loose hanging clothing and jewelry such as watches, rings or necklaces should not be worn around moving machinery. If you have long hair restrain it with a cap or net. Wear proper gloves only when essential, such as for handling rough, sharp or hot parts. Never Wear gloves when they can become entangled in the machine.

A number of types of protective equipment are available which can help you to avoid injury. Always wear approved eye or face protection and keep it clean.

Wearing safety toe shoes with skid-proof soles will help to prevent injuries. Wear a safety hat if required by your company's safety standards. Keep your protective equipment in good condition and be sure it meets or exceeds any required or recommended standards.

YOUR WORK AREA:

Always keep your working area clean. Dirty work areas with such hazards as oil or water on the floor may cause someone to fall to the floor, into the machine or onto another object resulting in serious personal injury.

S-3

Make sure your work area is free of hazardous obstructions and be aware of protruding machine members while working around the machine. Keep materials and equipment out of the aisles. Equipment should be returned to its proper storage place after use. Keep your workbench neat and clean, keep tools and work pieces in order.

Place oily rags in covered metal containers and throw all trash and scrap in the proper waste containers. Nails, broken glass and chips are particularly dangerous.

Always use a broom and pan; never pick them up with your bare hands or serious cuts can result. Remove nails from lumber or containers that must be handled by yourself or others.

If work platforms are used around the machine make sure they are sturdy with anti-slip surfaces. Report worn or broken flooring, stair treads, handrails or any other unsafe condition to your supervisor. When climbing, make sure ladders and scaffolds are strongly built and in good condition. Never climb on stock, machines or makeshift "ladders" built of skids, tote pans, boxes, etc.

YOUR TOOLS:

Always handle cutting tools with gloves or a shop cloth as new or reground tools have very sharp edges and careful handling can prevent unnecessary cuts.

Carefully inspect the tools for cracks or flaws and use only properly sharpened tools. Dull or improperly sharpened tools can break causing serious injury to yourself or others.

Use a cloth rag to wipe the tools free of grease, coolant or cutting fluids making certain the spindle is stopped and the machine is not in cycle. Maintain tooling in good condition by replacing worn adjusting nuts, clamp nuts, etc.

Store cutters and tools in a safe manner with cutting edges down or coated with plastic so that you will not be injured by accidentally striking them with a part of your body. Wrenches, tools and other miscellaneous parts should be kept off the machine table, and all moving units of the machine. Avoid using the machine elements as a workbench.

When improperly used, compressed air can be dangerous and result in serious injury. Never use compressed air for cleaning the machine, the work area, workbench, tools, work pieces, measuring instruments or clothes. Use care to prevent air blast from air operated tools from carrying chips and dirt in your direction or toward others. Don't blow air toward other people or machines; the air nozzle itself may contain small chips.

S-4

LIFTING AND CARRYING:

Improper lifting or carrying can result in serious injury, especially back injury. The following suggestions may help you avoid injury:

Size up the load first for weight and size. Inspect the load for nails or other protrusions that might cause injury. Get help before you handle a large or very heavy object.

Get a good grip on the object. Lift slowly by straightening your legs. (Keep your back relatively straight. Your leg muscles, not your back, should do the work.)

Keep the load close to your body as you come up.

Lift the load to the carrying position. If necessary to change your direction when in the upright position, turn your body with changes of foot positions. Be careful not to twist your body.

If you set the load on a bench or table, place it on the edge to make the table take part of the weight. Then, push the load forward using the arms or, if necessary, part of the body.

If you must lift the object higher than your waist, first lift the load waist high (using the procedure just described), then rest it on a support while you change your grip. Now bend your knees again to give added leg-muscle power for the final lift.

When carrying an object, always have a clear vision over the load.

While carrying an object, do not try to change its position or adjust your grip while you are in motion. If the load interferes with normal walking, get help.

When putting the load down to the floor surface from a waist-high carrying position, bend the knees and, with a straight back and the load close to the body, lower the object with the arm and leg muscles.

Use power hoists or other mechanical lifting and carrying equipment for heavy objects that exceed weights set forth by safety standards or by your own physical limitations. Bulky or hard to handle objects should also be lifted or carried with the aid of mechanical devices rather than by hand. This can help to avoid injury. Use hookup methods recommended by your safety department and know the signals for safely directing a crane operator.

S-5

WARNING: Regularly inspect slings, chains, hoists and other lifting devices. For frequency of inspection refer to the Williams- Steiger Occupational Safety and Health Act 1910.179, and any instructions applicable to the equipment. Any unsafe equipment should be repaired properly or discarded immediately. Use of unsafe lifting equipment can result in serious injury to yourself or others.

WARNING: Cranes, hoists, slings, eyebolts and other lifting equipment have safety rated capacities which should never be exceeded.

Be sure the equipment is adequate for the load and application.

Refer to standards and instructions applicable to any lifting equipment you use. (For example, ANSI Standard B18.15 available from The American National Standards Institute, Inc., 1430 Broadway, New York, New York 10018, contains information concerning safe lifting loads for different size eyebolts.) Overloaded or unsafe lifting equipment can result in serious injury to yourself or others.

WARNING: Never place any part of your body under a suspended load or move a suspended load over any part of another person's body.

Be certain that you have a safe spot for depositing the load before lifting. A falling load, for whatever reason, can result in serious injury or death.

OCCUPATIONAL SAFETY AND HEALTH ACT (O.S.H.A.) COLOR CODING

SYSTEM:

The Occupational Safety and Health Act (O.S.H.A.) has designated a color coding system for the marking of various areas on machine tools. This color coding system is designed to point out the various areas on the machine tool which are shielded or guarded, the potential pinch points and the areas of other potential hazards. Since safety to the operator, as well as maximum productivity of the machine tool, is of the utmost concern, everyone who comes in contact with the machine should read and understand the color coding system which follows:

WARNING: Machines built by The Cincinnati Gilbert Machine Tool Company, LLC are not painted in conformance with the O.S.H.A. color coding standard unless they are so ordered. If

S-6 the purchaser does not order the machine color coded, it is the purchaser's responsibility to paint the machine so it does conform with O.S.H.A. Color Coding Standard.

"Stop buttons or electrical switches used for emergency stopping machinery shall be RED."

"ORANGE shall be used as the basic color for designating dangerous parts of machine or energized equipment which may cut, crush, shock or otherwise injure, to emphasize such hazards when enclosure doors are open or when gear, belt or other guards around moving equipment are open or removed, exposing unguarded hazards."

"YELLOW shall be the basic color for designating caution and for marking physical hazards such as: Striking against, stumbling, falling, tripping and 'caught in between'. Solid yellow, yellow and black stripes, yellow and black checkers (or yellow with suitable contrasting background) should be used interchangeably, using the combination which will attract the most attention in the particular environment."

"Colors shall meet the tests specified in Section 3, Color Definitions, of ANSI Z53.1- 1967. Safety Color Code for Marking Physical Hazards."

NOTE: The color ORANGE should never be exposed when all safety guards and covers are properly in place.

When surfaces of the machine have been color coded for safety precautions, this identity should be maintained as well as the exact original color.

INSTALLATION AND RELOCATION:

When your machine first arrives at your plant or when it is relocated, certain safety precautions are in order.

Do not attempt to lift the machine before consulting the operator's instruction manual for proper methods and procedures. Read and completely understand the installation instructions in the machine service manual before attempting installation. Also refer to these instructions when relocating the machine. Be sure your lifting equipment is rated for safe lifting well above the machine weight.

Always check that all lubrication points on the machine have been filled with the proper amount and type of lubricant before attempting to run the machine. Refer to

S-7 the lubrication chart and diagram in the service manual or operator's instruction manual for the location of lubrication points, frequency of attention, special instructions and type of lubricant.

Only qualified electrician, designated to work on machine tool circuits, should be allowed to perform maintenance or "hook-up" of the electrical system. Read and completely understand the electrical schematics for the machine. After "hooking up" the machine you should test all aspects of the electrical system for proper functioning. Be sure the machine is grounded properly and check that all exposed electrical systems are covered properly. Place all selector switches in their "OFF" or neutral (disengaged) position; be sure that machine pushbuttons, manual limit switches or controls are set for a safe set-up; and check that the doors of the main electrical cabinet are closed and that the main disconnect switch is in the "OFF" position before you can consider the "hook-up" job completed.

If, for any reason, the electrical work cannot be completed and the machine must be left unattended, always lock the main disconnect switch in the "OFF" position.

Never bypass or wire around safety limit switches.

SAFETY IN SET-UP AND OPERATION:

Do not attempt to set up or operate this machine or perform maintenance on it until you read, know and practice all the safety instructions in this manual. These include general safety instructions, safety instructions for set up, operation and maintenance and the explanation of O.S.H.A. color coding. Know and practice safety rules set forth by your company. Failure to act in a "safety-minded" manner can result in serious injury to yourself and others.

When the machine is installed, be sure that the motors rotate in the proper indicated direction.

WARNING: Operators and maintenance personnel shall carefully read, understand and fully comply with all machine mounted warning and instruction plates. Do not paint over, alter or deface these.

plates or remove them from the machine. Replace all plates which become unreadable. Replacement plates are available on request from The Cincinnati Gilbert Machine Tool Company, LLC. Certain safety guards, covers and protective devices have been provided for the machine. Do not operate the machine with these disconnected, removed or out of place.

Additional guards may be necessary, and it is the responsibility of the employer to furnish any additional protective devices

S-8 required, including "point of operation" guarding. Failure to observe and abide by these warnings and instructions, or operation of a machine without necessary guards and protective equipment can result in serious injury to yourself and others.

Only qualified personnel, instructed in safety and all machine functions, should be entrusted to operate this machine. Use only the machines you are authorized and qualified to use.

Familiarize yourself with the machine before attempting to set up or operate it.

Respect its power and capability. Know where all stop buttons are located in case of emergency and be familiar with warning lights or signals that warn of a malfunction. Know the controls and all external moving parts of the machine. Read and understand the operator's instruction manual and operate the machine only as set forth in the manual.

WARNING: Safety stop dogs, limit switches, interlocks, etc. are provided for the various slides. Do not remove them or bypass them in an effort to obtain more travel or take a "short cut". serious damage to the machine or injury to the operator or others can result. If the job requires greater range, the work must be performed on a machine with greater travel.

Before setting up or operating a machine, be sure all guards are in place. These guards are designed to protect not only the operator but anyone who might accidentally fall against the moving parts of the machine. Be certain that all slide clamps are loosened before trying to move the slides.

Before setting up a workpeice or fixture, be certain it is a safe distance away from the cutting tool and position it so that a force does not have to be exerted toward the cutter. Also, retract the workpiece a safe distance from the cutting tool and stop the spindle when loading and unloading. Striking against a cutter, even when it is not in motion, can result in serious injury. When tightening or loosening a fastener, maintain secure footing in case the tool slips.

Mount your fixture or workpiece as close to the column side of the table as is possible. Use an arbor or adapter with the largest diameter and shortest length that can be used for the job and mount the cutter as close as possible to the spindle nose.

S-9

Burr and clean workpieces. Clean vise jaws or locating surfaces before positioning work on them. Position the work correctly in the holding device and use consistent pressure when tightening.

When using clamps and "hold down" bolts, the "hold down" bolts must be placed closer to the work than to the clamp supports. When using flat clamps the clamp supports must be level with the work or fixture being clamped or slightly higher, never lower. For heavy cuts, it is advisable to bolt a stop on the table against the fixture or workpiece to help absorb the thrust of a cut.

Never hammer or force any part of the machine to make it work. If it is necessary to strike the workpiece or fixture for adjustment, use a babbit or soft hammer.

Perform only work for which you are authorized and qualified and only after having been instructed properly. Never try to do work to which you have not been assigned, such as making electrical repairs. No one but an authorized electrician should do this work.

Perform all set up work, including adjustment of coolant delivery pipes, with the spindle stopped and with power disconnected. Use correct machining procedures including appropriate feeds and spindle speeds for the job. When in any doubt, consult with your supervisor before going any further.

Clean the spindle nose before mounting cutters or tools. Cutting tools are made for right or left have rotation; be sure that the direction of spindle rotation is correct for the tool being used. Be sure all tools are firmly seated in the spindle and clamp all work and fixtures securely before starting the machine.

After the initial setup, carefully feed the work holding device (without part) past the cutter to test for correct positioning of the machine slides. When adjustments are necessary turn off the power and wait until the machine has come to a standstill.

Do not attempt to brake or slow down moving machinery with your hand or with some makeshift device. Never attempt to use machine power to remove a nut from any shaft or cutting tool holder. Change tooling, spindle speeds and feedrates only when the spindle and slides are stopped. The same holds true for reversing the direction. The spindle and slides should be stopped when you measure workpieces or remove chips and grit. Chips and grit should be removed with a chip rake or brush, not with your hands.

Keep all parts of your body off the machine table, table edge, out of the path of moving units, trip dogs, trip plungers, and out of the "danger area" during machining operations. Never lean on a machine or reach over or through a machine - you can

S-10 get caught in cutting tools and other moving elements or you may accidentally push start buttons, feed controls, rapid traverse controls or power work holding controls.

During operation be attentive to the machining process. Excessive vibration, unusual sounds, etc., can indicate problems requiring your immediate attention.

Watch for conditions such as packed chips which can cause breakage of tools or machine elements.

Keep your machine in good operating condition at all times. It should be inspected regularly for parts that show wear or abuse. These should be replaced with authorized replacement parts only. Report any unusual sounds, smoke, heat, damaged components, etc. to your supervisor. Keep your coolant or cutting fluids clean; don't contaminate them with foreign matter.

Shut off the power to your machine if you leave the operating area; never leave a machine running unattended. Always turn the master disconnect switch to the OFF position before attempting to clean the machine at the end of the working day or if guards or covers are removed that would expose hazardous areas.

Never alter, or try to alter the machine, or any of its safety equipment at any time.

The guards are on the machine for the operator's safety, and when removed, serious injuries to the operator or others may result.

MAINTENANCE SAFETY:

WARNING:

19*

Do not attempt to perform maintenance on this machine until you read, know and practice all the safety instruction in this manual including general safety instructions; safety instructions for set up, operation and maintenance; and the explanation of O.S.H.A. color coding. Know and practice safety rules set forth by your company. Failure to act in a "safety-minded" manner can result in serious injury to yourself and others.

Only a qualified serviceman or maintenance man should perform maintenance and repair work on this machine. You should consult the service manual before attempting any service or repair work, and when in any doubt, contact The Cincinnati Gilbert Machine Tool Company, LLC office. Use only The Cincinnati Gilbert Machine Tool Company, LLC replacement parts; others may impair the safety or operation of the machine. Warning or danger signs should be placed conspicuously about the machine before performing maintenance or service work.

Vertical sliding members should always be blocked before detaching counterweights or driving mechanisms.

Orange identifying markings on the inside of covers, guards, etc., indicate that they are to be remounted immediately after adjustments have been made to components under them. Always keep the electrical enclosure doors closed. These doors should be opened only by a qualified electrician.

When working on any component always be sure it is safely positioned on a sturdy workbench. Never work on a component while it is hanging from a crane or other lifting mechanism.

WARNING: Before removing or opening any electrical or mechanical guard, cover, plate or door, be sure that the main disconnect switch is in the OFF position. If any tool is required to remove a guard, cover, bracket or any basic part of this machine, place the main disconnect switch in the OFF position, lock it in the OFF position if possible, and post a sign at such disconnect switch indicating that maintenance is being performed.

Whenever work is to be performed in an area away from the disconnect and the disconnect is not locked, TAG it and ALL start buttons with an "OUT OF ORDER" or "DO NOT START" tag. Adequate precautions, such as locks on circuit breakers, warning notices or other equally effective means should be taken to prevent electrical equipment from being electrically charged when work is being performed.

Be sure all guards, covers, plates or doors are closed and securely fastened before power is reconnected.

Failure to follow any of the above instructions can result in serious personal injury.

Before attempting to adjust, repair or perform maintenance on electrical circuits connected with yellow wires, first find the source of power; turn it off; and LOCK IT IN THE OFF POSITION. Machine tool interlock control circuits connected with yellow wires may be powered from a source away from the machine. They may carry voltage even when the machine's main disconnect switch is turned to the OFF position.

S-12

Keep working space around electrical equipment clear of obstructions and so arranged as to give authorized persons ready access to all areas requiring attention. Adequate illumination should be provided to allow for proper operation and maintenance.

Keep all operating electrical equipment in safe and proper working condition.

Defective equipment should either be put in good order or permanently disconnected. Thoroughly inspect infrequently used electrical equipment before use to determine its fitness for service.

Use tools for their intended use only. Check tools and equipment frequently. Never use worn tools, frayed extension cords, etc. Be sure that all electrical equipment is properly grounded. "Short-cuts" and "Safety-mindedness" are not compatible.

TOOLING SAFETY:

Cincinnati Gilbert Machine Tool Company, LLC manufactures machines with two entirely different tooling systems: ANSI B5.18 (figure S-1) and ANSI B5.50 (figure S-2). These systems are not interchangeable with each other, and constitute a safety hazard if mixed with each other or any other system.

WARNING: Never interchange tooling from one machine to another unless you are positive that they are the same. Failure to follow this warning could result in serious personal injury and / or damage to the machine took

S-13

#50 Taper 3.500 per foot

Figure S-1, ANSI B5.18 Tool Shank

\I

\I-- — =_.=

1.000-8 Thread

2.750 Gage Diameter

#50 Taper 3.500 per foot

2.750 Gage Diameter

Figure S-2, ANSI B5.50 Tool Shank and Retention Knob

SECTION I

INTRODUCTION AND DESCRIPTION

1.1 GENERAL INFORMATION

This manual contains installation, operation and maintenance instructions for the 5 and 6 Inch Spindle, Series D, Floor Type Horizontal Boring Machine (hereafter referred to as machine) manufactured by the Cincinnati Gilbert Machine Tool Co., LLC, Cincinnati, Ohio.

1.2 MANUAL SCOPE

The contents of each section are:

SECTION I, INTRODUCTION AND DESCRIPTION, contains introductory descriptive information about the machine.

SECTION II, UNPACKING, INSTALLATION AND PREPARATION FOR

OPERATION, contains instructions required for handling the machine from time of receipt until the machine is installed and checked out for production operation.

SECTION III, OPERATING INSTRUCTIONS, contains instructions required for production operations the operator must know. Instructions related to CNC are included in a CNC manual. (Refer to table 1-2).

SECTION IV, PERIODIC MAINTENANCE, contains detailed instructions for performing required periodic maintenance, lubrication and inspection.

SECTION V, GENERAL MAINTENANCE, contains detailed explanations of the operating systems, a troubleshooting table and specific maintenance instructions.

SECTION VI, MANUFACTURERS DATA, contains data prepared by manufacturers whose products are incorporated in the machine. This data may consist of maintenance information and/or repair parts information. In addition to data in Section VI, other manufacturers' manuals are sent separately. (Refer to paragraph 1.8).

1-1

HEAD

SERVO

MOTOR

COLUMN

MAGNETIC

CONTROL PENDANT

HEAD

SPINDLE

CROSS SLIDE

FERRAND

RUNWAY

HOLD-DOWN

BOLTS AND

JACK SCREWS

*Only on HJX Machines.

NOTE: THE NUMBER OF RUNWAY

SECTIONS VARIES WITH THE

MACHINE

PENDANT

BOOM

Il

CLUTCH HOUSING

AND SPINDLE

SERVO MOTOR

REAR

RUNWAY

SECTION

CROSS

SLIDE'

RUNWAY KEY

AND KEYWAY COLUMN BASE

FRONT RUNWAY

SECTION

HEAD VERNIER ROD

HEAD COUNTERWEIGHT

CHAINS

HEAD FERRAND

HEAD COUNTER-

WEIGHT CHAINS

RUNWAY

POWERTRAK

COLUMN BASE

FERRAND

Figure 1-1. Component Location, Front View

CROSS SLIDE

SERVO MOTOR

CENTRALIZED

LUBRICATION

PUMP AND

RESERVOIR

(See Section IV)

COLUMN

BASE GEAR

MOTOR

CROSS SLIDE

POWERTRAK

qgpt:::71

Figure 1-2. Component Location, Rear View

1.3 NOTES, CAUTIONS AND WARNINGS

Notes, cautions and warnings are used throughout the manual to emphasize important and critical instructions.

NOTE:

A note is used to emphasize operating procedures, practices, etc.

that should be complied with.

CAUTION: A caution is used to emphasize operating procedures, practices, etc. which, if not strictly complied with, may result in damage to or destruction of equipment.

WARNING: A warning is used to emphasize operating procedures, practices, etc. which, if not strictly complied with, may result in personal injury or loss of life.

1.4 GENERAL DESCRIPTION

The machine is a four to seven axis machine used for heavy milling operations and accurate boring operations. The machine may be operated in CNC (automatic) mode or manual mode. During CNC mode operation, programmed operations may be augmented by manually controlled operations.

The seven operational axes are:

1. W axis, Cross slide + and - travel

2. X axis, Column + and - travel on runway

3. Y axis, Head + and - travel on column

4. Z axis, Spindle + and - travel

5. B axis, Rotary table + and - travel (Not shown)

6. A axis, CNC Head tilt + and - travel (Not shown)

7. C axis, CNC Head rotation + and - travel (Not shown)

The direction of + and - travel for the cross slide, column, head, and spindle, is indicated on figure 1-3.

AC servo motors move the cross slide, column, head and spindle through a ball nut and ball screw drive train. During CNC mode operation, drive is controlled by the programmed tape. During manual mode operation, drive is controlled by manual placement of switches mounted on the pendant control. (See figure 3-2).

AC servo motor move the rotary table through an anti-backlash drive train. During CNC mode operation, drive is controlled by the programmed tape. During manual mode operation, drive is controlled by manual placement of switches mounted on the pendant control. (See figure 3-2).

1-2

Spindle shifting functions are hydraulic controlled. Hydraulic power is generated by a motor driven hydraulic pump, the head lube pump. This pump also pumps oil, for lubricating purposes, to mechanisms inside the head.

A centralized demand type lubrication system provides automatic positive lubrication for the feed screws and ways related to the saddle, table and head. When movement along any axis is initiated, a related solenoid valve opens and the system injects oil to moving components. Oil continued to be injected, on a time cycle basis, as long as travel is maintained.

The rotary table has a self contained, positive displacement type lubrication system.

The base is the reservoir, and the system is driven by air pressure.

1.5 MAJOR MACHINE COMPONENTS

Major machine components are:

1. Runway

2. Column base

3. Cross slide

4. Column

5. Head

6. Counterweights

7. Pendant Control

8. Rotary table 9, CNC Milling attachment

RUNWAY: The runway (see figure 1-1 and 1-2) is formed of one or more sections, depending on how much column travel is required. The runway supports the column base.

COLUMN BASE: The column base (see figure 1-1 and 1-2) supports the column or optional cross slide. The column base servo motor is mounted on a gear box attached to the column base. The column base is driven along the X+ and X- axis by a rack and pinion connected to the column base gear box.

CROSS SLIDE: The optional cross slide (see figure 1-1 and 1-2) supports the column. The cross slide servo motor is mounted to a gear box attached to the cross slide. The cross slide is driven along the W+ and W- axis by a feed screw connected to the servo motor and a ball nut attached to the column base.

COLUMN: The column (see figure 1-1) consists of a single cast section attached to the column base or cross slide. The head servo motor is mounted to a gear box on top of the column.

HEAD: The head (see figure 1-1) contains the spindle and spindle drive gearing.

The head is clamped onto the column and positioned by two taper gibs and four flat gibs. The spindle positioning servo motor, main drive motor, and tool lock motor are attached to the head. The head is driven along the Y+ and Y- axis by a feed screw connected to the head servo motor and a ball nut attached to the head.

COUNTERWEIGHTS: (In! interweight assemblies (see figure 2-5) act as a counterbalance for the head. They are enclosed in the column, and connected to the head by two link type chains. Each chain makes a 90° break around two spur type sprockets. The sprockets are mounted on two sheave brackets attached to the column.

HYDRAULIC COUNTERBALANCE: The hydraulic counterbalance permits compensation for the additional weight of the CNC milling attachment when it is mounted on Machine "B". It consist of a ram type hydraulic cylinder inside the column, with the valving and controls for its operation located on the outside of the column.The hydraulic counterbalance is attached to the head by two link type chains. Each chain makes a 90° break around two spur type sprockets. The sprockets are mounted on two sheave brackets attached to the column.

PENDANT CONTROL: The pendant control (see figure 1-1) is suspended from the pendant boom by a counterweight loaded cable. The pendant houses switchesk, controls and indicators required for machine operation.

ROTARY TABLE: The rotary table is fastened to the floor plate. The rotary table servo motor is attached to the table base and drives the table top around its CW+ and CCW- axis by an anti-backlash gearbox.

CNC MILLING ATTACHMENT: The milling attachment is automatically lifted and hydrauliclally clamped to the machine head from the storage cradle. The A+ and A-tilting motion and the C+ and C- rotary motion are driven by AC servo motors.

AUTOMATIC TOOL CHANGER: The tool changer contains space for multiple tools, and is powered by hydraulic motors. The maximum weight for a tool is 50 lbs., the maximum diameter for a milling cutter is 6" when put in adjacent sockets, it is 12" when-the adjacent socket is left empty. The maximum tool length is 23", gage line to tool tip.

1-4

1.6 AUXILIARY COMPONENTS

Major machine auxiliary components are:

NOTE: Refer to figure 1-4 for the location of these components.

1. Contouring Numerical Control

2. AC Axis Feed Dive

3. Spindle AC Speed Control Drive

4. Programmable Control

5. Refrigeration Unit

6. Magnetics and Interface Control

7. Main Disconnect Switch

8. Jet pulser unit 9.

COUTOURING NUMERICAL CONTROL: The CNC governs machine operation when the machine is operated in CNC mode. Operation of this control is interfaced with the pendant control. (The CNC is located in the magmetics & interface cabinet.)

AC FEED DRIVE: The Linear and Rotary AC Axis Feed Drives govern and monitor servo motor operation in all axes. (The drives are located in the magnetics & interface cabinet.)

SPINDLE DRIVE: The spindle drive is a variable speed AC motor, coupled with the three speed heariqtOrk provides an infinitely variable speed control within each range.

PROGRAMMABLE CONTROL: Allows the operator to control all aspects of machine functions in a semiautomatic manner, such as lubrication, shifting and control of all axes. (Located on operators platform.)

REFRIGERATION UNIT: The refrigeration unit (see figure 1-4) is a self contained unit that maintains oil pumped by the hydraulic (head lube) pump within specified temperature limits. Operation is interfaced with the pendant control. If operation is selected, temperature of the circulating oil is controlled by automatic on-off cycling.

MAGNETICS AND INTERFACE CONTROL: The magnetics and interface control (see figure 1-4) houses devices (relays, terminals, etc.) for interfacing the CNC and AC Feed Drive to the system. Three phase motor starters, thermal overloads, and all fuses are located in this control.

MAIN DISCONNECT SWITCH: Operating electrical power is connected to the service side of the main disconnect switch (see figure 1-4). Closing the disconnect switch energizes machine primary circuits.

WARNING: Open the main disconnect switch before performing any maintenance on the machine. Attach a red tag to the pendant if the switch must be closed when maintenance is being performed. (Refer to paragraph 2.7.3).

1-5

JET PULSER UNIT: The jet pulser unit (see figure 1-4) supplies flood coolant either through the spindle or through an adjustable nozzle on the front of the head. This unit will also supply high pressure coolant through the spindle for deep drilling and boring operations.

WARNING: Do not put high pressure coolant through the CNC milling attachment. Doing so could cause damage to the milling attachment. :-t**1:•004e-iyY.

1.7 IDENTIFICATION AND DATA PLATES

The machine data plate, with the serial number and other pertinent data, is attached to the magnetics cabinet. The serial number is also etched or stamped in the top of the front column way. Other major components, (AC drives, motors, pumps, etc.) have individual data plates. Information on these data plates should be included in all related correspondence with The Cincinnati Gilbert Machine Tool Co., LLC.

1.8 RELATED PUBLICATIONS

Publications required for instruction and parts support information for auxiliary equipment are supplied with the machine by The Cincinnati Gilbert Machine Tool Co., LLC.

1-6

I

(HEAD)

"Y" AXIS

1, it --1

4111.

"Z" AXIS

SPINDLE

.....M.1

Figure 1-3. Axis Movement

1-6

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Figure 1-4. Foundation and Location of Auxiliary Components

SECTION II

UNPACKING, INSTALLATION AND

PREPARATION FOR OPERATION

2.1 GENERAL

This section contains instructions for unpacking, installing and preparing the machine for production operation.

2.2 SPECIAL TOOLS

Only tools normally required for rigging and installing heavy precision machines are required to install the machine.

2.3 CUSTOMER FURNISHED MATERIALS REQUIRED FOR INSTALLATION

The customer must supply certain items required to install the machine. These items are identified throughout this section with the related text.

2.4 DISASSEMBLY PRIOR TO SHIPMENT

After final test the machine was disassembled for shipment as follows:

a. All wiring was removed from the wire ducts and the ducts disassembled into basic lengths.

b. The control boom and pendant control were removed.

c. The magnetics control was removed from the column.

d. The counterweights were removed from the column.

e. The column was removed from the column base or cross slide

NOTE: If the machine has a cross slide, the cross slide and column base were left attached to a runway section as an assembly. If the machine has only a column base, it was left attached to the column base.

f. The entire machine and auxiliary components were preserved for long term covered storage.

2.5 RECEIVING INSPECTION

Upon delivery visually inspect the crates and visible parts of the machine for shipping damage. If a crate or cover is damaged, or signs of possible damage are evident, have the carrier note the condition on the shipping papers before signing the shipping receipt, or zdvise the carrier of the condition as soon as possible. Any verbal notification should be confirmed by a written claim as soon as possible.

2.6 FOUNDATION REQUIREMENTS

A Cincinnati Gilbert Horizontal Boring, Drilling and Milling Machine represents a major investment made to perform machining operations accurately in a minimum amount of time. Productivity, 2.1 machine alignment, accuracy of operation and maintenance are directly affected by the foundation that supports the machine. The importance of a properly constructed and adequate foundation cannot be over emphasized.

NOTE: Refer to table 1-1 for weights that must be considered when designing and constructing a foundation.

NOTE: The following foundation recommendation data is based on the premise the soil will have a minimum bearing of 3000 lb. per ft., a maximum moisture content of 15 to 20 % and that it extends 4 to 6 ft. below the floor line.

Soil conditions should be verified by taking boring samples at the exact place the foundation is to be constructed.

The following factors must be considered when constructing a foundation.

CAUTION: A well designed and constructed foundation is essential for accurate machine operation. A foundation that does not provide adequate support and anchor contributes to inaccurate machining and excessive maintenance.

a. The foundation must have sufficient strength and mass to provide rigidity to hold the machine bed level. In addition, the foundation strength and mass must be capable of absorbing vibration and dampening resultant chatter.

b. The foundation must provide adequate support for the machine, auxiliary equipment and maximum weight work pieces without movement throughout the travel range of the moving loads of the machine.

c. The foundation must provide for installation of hardware required to securely tie the machine to the foundation, to level the machine, and to maintain it level.

The design, configuration, arrangement of reinforcing bars, depth and slump are determined by both the local soil bearing conditions and the machine configuration. It is strongly recommended that the foundation be designed by a Registered Professional Engineer familiar with local conditions and experienced in designing and supervising construction of foundations for heavy equipment.

NOTE: The engineer should also supervise actual construction of the foundation and control the type concrete (moisture content, grade, etc.) used.

The foundation must be isolated from transmission of vibrations from outside sources. If vibration conditions exist, the evacuation walls should be lined with a resilient material.

The foundation should extend, as a single unit, beneath the entire machine and encompass all external devices associated with the machine. These include runways and auxiliary equipment 'such as rotary tables, bed plates, and box tables. The maximum predetermined thickness should be uniformly maintained throughout the foundation. If cooling troughs, wiring ducts, etc., are cast in the foundation, provisions for additional reinforcement must be included in the design.

2-2

NOTE: It is recommended a wooden form be constructed that will accurately hold the hold-down bolts (See figure 2-1.) in position (See figure 1-2.), while the concrete is being poured. The hold-down bolts should be suspended so their upper surface is flush with the top or flush with the trough.

Drawings and instruction data related to recommended hold-downs and leveling procedures are included in this manual, or will be furnished.

NOTE: The Cincinnati Gilbert Machine Tool Co. assumes no responsibility for the foundation. However, the Company will review any foundation design submitted and offer comments. A copy of the final foundation design should be forwarded to the Company for future reference.

The means provided for anchoring the machine to the foundation are equally as important as the foundation. The anchor hold-down assemblies must function as a clamp and grip the machine and foundation together with vise like action. The design of The Cincinnati Gilbert Machine Tool Co.

Leveling Screw Hold-down Assembly (See figure 2-1.) has been proved in many hundreds of installations of our machines and machines manufactured by others. The Company strongly recommends this leveling screw hold-down assembly be used. If this assembly is not used, a similar one can be fabricated, or purchased from:

Decatur Engineering Co.

P.O. Box 643

Decatur, IL 62525

CAUTION: If recommended leveling screw hold-down assemblies are not used, a a deviation, having the approval of The Cincinnati Gilbert Machine Tool

Company, must be obtained or warranty terms may be affected.

The leveling screw hold-down assembly essentially consists of a box, welded at the bottom, enclosing a large square nut. The hold-down bolt is screwed into the nut. The tube between the box and leveling plate functions as a barrier that provides clearance around the assembly when concrete is poured. The tube fit between the tube and leveling plate should be loose. The tack weld attaching the tube and leveling plate merely holds the tube and plate in position during foundation construction. When the foundation concrete hardens there will be some concrete shrinkage away from the box and plate. As the machine is leveled, and the hold-down nuts tightened, the box may crush some of the concrete above it, and the leveling plate will move slightly downward, compensating for the shrinkage. In order for this to happen, and the hold-down to properly serve its function, the tack weld must break, and move slightly upward into the leveling plate.

It is necessary that the concrete under the leveling plates be sound and the plates well seated or the machine will not stay level throughout the travel range of the loads being worked. To check that the leveling plates are well seated, and there are no voids beneath them, tap each leveling plate with a hammer. The security of seating can be determined by the sound. If there is a void or loose sand under the leveling plate, the plate should be taken up and imbedded in the proper grade of Pro-Rok, Stonhard, or other similar material.

2-3

6"

444.

VIEW A—A

4" DIA. X IVTHICK PLATE

FURNISHED BY CINCINNATI GILBERT

LEVELING PLATE

2' X6" X 6"

LIGHT TACK WELD

TWO SPOTS ONLY

• • 14 O.D. X 4 /2 LONG

COLLAR 7/8-9 N.C.TAP THRU

7;X 9 N.C. X 15" STUD

2"STANDARD PIPE

16 1/p LONG

WELD ALL AROUND

21/p THREAD

13/;-12U N. JACK SCREW

FURNISHED BY CINCINNATI GILBERT

13/:4'-I2 U.N. HEX NUT

FURNISHED BY CINCINNATI GILBERT

IY2 THREAD

s •

9 "z" $0 yeP

743 -9N.C. X II"

STUD

• I 1/2 MINIMUM

"11"1 " "

21/2 THREAD

NOTE: ()FOUNDATION STUDS AND

LEVELING PLATES ARE TO

BE FURNISHED BY THE

CUSTOMER.

2)LIGHT TACK WELDS ARE TO

BREAK AWAY WHEN TIGHTENING

ANCHOR BOLTS.

CROSS SECTION THRU RUNWAY HOLD-DOWN

AND JACK SCREW ASSEMBLY

Figure 2-1. Runway Hold-Down and Jack Screw Assembly

2-4

2.7 INSTALLATION SAFETY PRECAUTIONS

Installation safety precautions must be complied with when installing the machine to avoid improper operations that may result in injury or death.

WARNING To ensure maximum safety, installation personnel must understand and comply with the following installation and safety precautions included in paragraphs 2.7.1 through 2.7.5. These paragraphs are referenced with the related installation instructions.

2.7.1 LIFTING AND MOVING MAJOR COMPONENTS. Major components should be lifted and moved with rigging and overhead crane. The approximate gross weight for each major component

(bed, colum, etc.) is included with the related installation instructions. All rigging equipment used for lifting components must be equal to lifting the actual weight plus 50%. This 50% safety factor is minimum. All rigging equipment must be inspected for faulty condition (bent beams, frayed or cut cables, loose clamps, proper size hooks, etc.)

WARNING: Use only lifting equipment in good condition, and rated for the weight of the component being lifted, plus 50%. Overloaded or faulty equipment may result in injury or death.

2.7.2 EYEBOLT USE. The lifting force applied to an eyebolt must be inline with the eyebolt thread centerline. The break load of an eyebolt is sharply reduced when the lifting force is angular to the eyebolt thread centerline.

Eyebolts must only be installed at points specified in the instructions. Installations at other points may result in the eyebolt being installed in holes not designed for lifting purposes.

WARNING: Install eyebolts only at specified locations. The Iiftting force applied to an eyebolt must be inline with the eyebolt thread. Improper use may result in serious injury or death.

2.7.3 MAIN DISCONNECT SWITCH. The main disconnect switch must be open (off) when any maintenance work is being performed on the machine. If, for any reason, the switch must be closed to perform maintenance, a red tag, stating that maintenance is being performed, must be attached to the pendant control.

WARNING: Open the main disconnect switch before performing any maintenance on the machine. Attach a red tag to the pendant if the switch must be closed when maintenance is being performed.

2.7.4 OPERATION WITHOUT WAY COVERS, GUARDS AND COVERS. The machine must never be used for production operation without all way covers, guards and covers properly installed. During erection and testing, it might be necessary to operate the machine without way covers, guards and/or covers being in place. If such operation is required extreme care must be taken not to wear loose clothing, and handle tools and/or rags so they will not be caught in rotating or moving components.

WARNING: Exercise extreme…