cincinnati C5000 User Manual

OPERATING/PROGRAMMING SUPPLEMENT

for CINCINNATI HA WK TURNING CENTER Model 150 / 200 / 250 (ERD) with F ANUC SERIES 21i CNC CONTROL

PUBLICATION NO. 91203597B001

IMPORTANT

Carefully read the instructions and safety precautions given in this manual. Do not attempt to operate this machine until you have thoroughly read and understood the material contained in this manual and all other applicable manuals.

Atthetime ofwriting,thebook wascompletely u p--to--date.However, due to continual improvements in design, it is possible that descriptions contained herein may vary to a slight extent from the system delivered to you. This merely implies thatthe system hasbeen improved to better fulfill your requirements.You areencouraged to contact the nearest Cincinnati Machine representative for clarification.

Patents Notice

Themachine and attachments and partsthereof illustrated and describedin this book are manufactured under and protected by issued and pending British and Foreign Patents and copyright is reserved in any originaldesign feature thereof and in the contents of this book and every part thereof.

IMPORTANT

Cincinnati Machine U.K. Limited P.O. Box 505, Kingsbury Road, Birmingham, B24 0QU

1998 Cincinnati Machine, a Division of UNOVA Industrial Automation Systems, Inc.

Cincinnati Machine, CINCINNATI, DART ,ARROW, SABRE, LANCER and HAWK are trademarks of Cincinnati Machine, a division of UNOVAIndustrialAutomationSystems, Inc.

ACRAMATIC is a trademark of Vickers E.S.D., Inc. Printed in England -- EDITION 1 -- June 1999

WARNING 1

In order to clearly show details of this machine, some covers, shields, guards, barriers, devices or doors have either been removed or shown in an ”open” position. All such protective components must be installed in position before operating this machine.

Failure to follow this instruction may result in personal injury.

WARNING 2

FOREWORD

The purpose of this manual is to provide the necessary information to enable suitably experienced personnel, to operate the CINCINNATI HAWK 150/200/250 Turning Centers equipped with Fanuc 21i control system.

Information contained in this manual is not warranted and is subject to change without notice.

Themanualhasnotbeenpreparedtoenableinexperiencedpersonnelto operate the machine without further training.

The owner/user is responsible for the training of inexperienced personnel and for providing the background necessary for experienced personnel to safely operate these m achines.

It is intended to cover t he control of the MTB (Machine ToolBuilders) dependant functions as applicatble to the HAWK TURNING MACHINE with Fanuc control.

It does not include general part programming or control maintenance information. These are covered in the appropriate GE FANUC Operators and maintenance manuals, as supplied with the machine.

CUTTING FLUIDS When soluble coolants are

used, it is important to ensure that recommended

The chapter on general safety precautions should be observed at all times during m achine operation and maintenance. Read this chapter before reading the remaining chapters in this manual and operating the machine.

concentration levels are maintained.

Failure to follow this instructioncan cause corrosion of safety critical parts, resulting in machine damage and/or serious personal injury.

Anyquestionspertaining to the operationofthemachineshould be directedto:

Field Service Department Cincinnati Machine Cincinnati Machine U.K. Ltd, Marketing Company, P.O. Box 505, Cincinnati, Kingsbury Road, Ohio 45209--9988, Birmingham, B24 0QU USA. England Main Tel: (513) 841--8100 Tel: 0121--351--3821 Service Tel: (513) 841 3000 Fax: 0121--313--1184 Service Fax: (513) 841 8871

DANGER HIGH VOLTAGE

Lethal voltages are present in the magnetics and electrical control cabinets when the MACHINE MAIN DISCONNECT is ’ON’. Current and voltage measurements shouldbe attempted only by qualified electrical maintenance personnel.

Before working on any electrical circuits, turn the machine Main Disconnect Device ’OFF’ and lock It. Capacitors in the ServoDrives requireupto 20 minutes tocompletely discharge. Alwaysverify thatdischarge

is complete using a known working and calibrated voltmeter before commencing work on these units. Unless expresslystated inapplicable CincinnatiMachine documentation or by the appropriate Cincinnati Ma-

chine Field Service Representative, do NOT work with electrical power ’ON’. If such express statement of advice exists, working with electrical power ’ON’ should be performed by a Cincinnati Machine Field Service Representative. Thecustomer and subsequenttransferees must determinethat any other personperforming work with electrical power ’ON’ is trained and technically qualified.

Failure To Follow This Instruction May Result In Death Or Serious Personal Shock Injury.

-- 1

Chapter 1

Safety Precautions 1--1.........................

Important 1--1...........................................................

General Safety Instructions And Considerations 1--2............................

Personal Safety 1--2...................................................

Work Area Safety 1--2.................................................

Tool Safety 1--3......................................................

Lifting And Carrying Safety 1--3.........................................

Installation And Relocation Safety 1--4....................................

Setup And Operation Safety 1--4.........................................

Maintenance Safety 1--5...............................................

Materials Used With This Product 1--6....................................

LIFTING DEVICES 1--7..................................................

GENERAL 1--7......................................................

EYEBOLTS 1--7.....................................................

HOIST RINGS 1--9...................................................

SPREADER BARS AND LIFTING BEAMS 1--10...........................

CHAIN 1--10.........................................................

CABLE SLINGS 1--12.................................................

SYNTHETIC MATERIAL SLINGS 1--13..................................

P TYPE HOOKS 1--14.................................................

S HOOKS 1--14.......................................................

U TYPE HOOKS 1--16.................................................

GENERAL SAFETY LIFTING INFORMATION 1--17........................

Fluids Used With Machine Tools 1--18........................................

General Considerations 1--18.............................................

Lubricants 1--18.......................................................

Cutting Fluids 1--18....................................................

Sources Of Information -- USA 1--18......................................

Usage Information 1--19................................................

Cutting Fluids -- Preventative Maintenance 1--20................................

See Cautions 1 and 2 1--20...............................................

Water Quality 1--20....................................................

Too Soft 1--20.........................................................

Too Hard 1--20........................................................

Cleaning The Coolant Reservoir 1--20......................................

Lifespan 1--21.........................................................

Tramp Oil 1--21.......................................................

Filtering 1-- 21.........................................................

Rust Prevention 1--21...................................................

Printed Circuit Board Handling Instructions 1--22................................

General 1--22.........................................................

Recommended Handling Procedure 1--22...................................

Safety Features 1--23......................................................

Perimeter Guarding 1--23................................................

Operator Sliding Door(s) 1--23...........................................

Table of Contents

Feed Hold Push Button 1--24.............................................

Emergency Stop Push Button 1--24........................................

Electrical Isolation Device (Main Disconnect Switch) 1--24.....................

Air Supply Isolation Valve 1--24..........................................

Metric Lifting Points 1-- 24...............................................

Machine Related Safety And Usage Notes 1--25.................................

Axis Overtravel Condition 1--25..........................................

Safe Operation Of Lathe Chucks 1--25.....................................

Work Holding Devices 1--25.............................................

General Operation 1--26.................................................

Battery Replacement 1--27...............................................

Lithium Batteries 1--27.................................................

Chapter 2

System Information 2--1........................

Introduction 2--1.........................................................

Guard Strength 2--2...................................................

Noise 2--3...........................................................

Fumes And Coolant Misting 2--4.........................................

Fire Hazard 2--4......................................................

Machine Location -- See Caution 2--4.....................................

EMC Directive Requirements 2--4........................................

NC Control 2--5......................................................

Machine Information 2--5..................................................

Axis Orientation 2--6.....................................................

Hawk Specification 2--7...................................................

Machine And Range Drawings 2--9..........................................

Motor Rating 2--25........................................................

MACHINE ALIGNMENT AND PROGRAM POINTS 2--27......................

Machine Zero 2--27....................................................

Chapter 3

Functional Description of Controls 3--1..........

Introduction -- GE FANUC 21i--TA CNC System 3--1........................

OPERATOR PANEL -- PUSHBUTTON DESCRIPTIONS 3--2.................

AUTOMATIC OPERATION -- PROGRAMME SOURCE 3--3....................

MEMORY OPERATION -- (Push button with LED) (A1) 3--3.................

EDIT MODE -- (Push button with LED) (A2) 3--3...........................

MDI OPERATION -- (Push button with LED) (A3) 3--3......................

EXECUTION PUSHBUTTONS 3--3.........................................

CYCLE START (Push button with LED) (F1) 3--3...........................

CYCLE STOP (Push button with LED) (F2) 3--3............................

PROGRAMME STOP (Push button with LED) (F3) 3--4.....................

SPINDLE CONTROL BUTTONS 3--4.......................................

SPINDLE STOP (Push button with LED) (F5) 3--4..........................

SPINDLE CLOCKWISE (CW) (Push Button with LED) (F4) 3 --4..............

Table of Contents

SPINDLE COUNTER CLOCKWISE (CCW) (Push button with LED) (F6) 3--4...

SPINDLE 100% (Push button with LED) (D5) 3--5..........................

SPINDLE SPEED INCREMENT (Push button with LED) (D6) 3--5............

SPINDLE SPEED DECREMENT (Push button with LED) (D4) 3--5............

OPERATION BUTTONS 3--5..............................................

ALIGN MACHINE -- (Push Button with LED) (A4) 3--5.....................

MPG MODE (HANDWHEEL) & INCREMENT SELECTION

PUSHBUTTONS 3--5..............................................

MPG MODE -- 0.001mm (Push Button with LED) (B4) 3--5...................

MPG MODE -- 0.010mm (Push Button with LED) (B5) 3--6...................

MPG MODE -- 0.100mm (Push Button with LED) (B6) 3--6...................

JOG MODE -- (Push Button with LED) (A5) 3--6...........................

OPERATION SELECT -- PUSHBUTTONS 3--6...............................

SINGLE B LOCK -- (Push Button with LED) (B1) 3--6.......................

BLOCK DELETE -- (Push Button with LED) (B2) 3--6.......................

OPTIONAL STOP -- (Push Button with LED) (B3) 3--6......................

DRY RUN -- (Push Button with LED) (C1) 3--6.............................

PROGRAMME TEST -- (Push Button with LED) (C2) 3--7...................

AXES INHIBIT -- (Push Button with LED) (C3) 3--7........................

AXIS/DIRECTION SELECTION PUSHBUTTONS 3--7........................

X+ AXIS (Push Button with LED) (B9) 3--7...............................

X-- AXIS (Push Button with LED) (D9) 3--7...............................

Z+ AXIS (Push Button with LED) (C10) 3--7...............................

Z-- AXIS (Push Button with LED) (C8) 3--7................................

RAPID TRAVERSE (Push Button with LED) (C9) 3--8......................

PARTS CATCHER DOWN (Push Button with LED) (A6) 3--8.................

PARTS CATCHER UP (Push Button with LED) (A7) 3--8....................

TURRET JOG + (INCREMENT) (Push Button with LED) (C4) 3-- 8............

TURRET JOG -- (DECREMENT) (Push Button with LED) (C5) 3-- 8............

CHUCK -- ID GRIP (Push Button with LED) (A8) 3--8.......................

CHUCK -- OD GRIP (Push Button with LED) (A9) 3--8......................

OFFSET MEASURE (Push Button with LED) (A10) 3--8.....................

TOOL SETTING ARM DOWN (Push Button with LED) (D2) 3--9.............

TOOL SETTING ARM UP (Push Button with LED) (D3) 3--9.................

PROGRAM RESTART (Push Button with LED) (D1) 3--9....................

AUX 1 -- Auxillary Push Button (Push Button with LED) (C6) 3-- 9.............

COOLANT BUTTONS 3--9................................................

COOLANT OFF (Push Button with LED) (F9) 3--9..........................

COOLANT ON (Push Button with LED) (F8) 3--9..........................

COOLANT AUTO (Push Button with LED) (F10) 3--9.......................

MISCELLANEOUS CONTROLS 3--10.......................................

MEMORY PROTECTION -- Keyswitch 3--10...............................

RS 232 SERIAL DATA PORT 3--10.......................................

FEED/RAPID/JOG OVERRIDE -- Selector Switch 3--10......................

EMERGENCY STOP (red mushroom pushbutton with latch) 3--10..............

MTB OPERATORS CONTROL PANEL 3--11..............................

Spindle Load Meter 3--11...............................................

Table of Contents

0 to 100% Range (Continuous rating) 3--11.................................

110 to 150% Range -- Yellow Band (30 minutes 50% rating) 3--12...............

151 to 180% Range -- Red Band (1 minute overload capacity) 3--12..............

MASTER START -- Illuminated push button 3--12............................

CYCLE START 3--12..................................................

HANDWHEEL (MPG) 3--13.............................................

CHUCK UNCLAMP push button 3--13....................................

CHUCK CLAMP push button 3--13.......................................

TAILSTOCK QUILL ADVANCE/STEP ADVANCE push button 3--14...........

TAILSTOCK QUILL RETRACT push button 3--14...........................

Machine Pressure -- Tailstock Thrust -- Chuck Drawbar Force -- Chuck Brake (Dampener) Control . .

3--15

MAIN POWER DISCONNECT SWITCH 3--16.............................

Optional Operating Devices 3--17............................................

Swarf Conveyor 3--17..................................................

Wash Gun 3- -18.......................................................

GENERAL CHUCK SAFETY GUIDELINES 3--19..........................

CHUCKS 3--20...........................................................

CHUCKING SYSTEM TYPES 3--20......................................

CHUCK 3--20............................................................

CENTRIFUGAL FORCE AND SPEED LIMITATIONS 3--20..................

CHUCK LUBRICATION 3--20...........................................

TOP JAW RECOMMENDATIONS 3--21...................................

Chapter 4

Machine Start Up and Alignment Procedure 4--1..

Machine Start Up and Alignment Procedure 4--1............................

General 4--1.........................................................

Start Up and Shut Down Procedures 4--1..................................

Start Up 4--1.........................................................

Shut Down 4--1......................................................

Machine/Control Alignment Procedure 4--2................................

Turret Alignment 4--2..................................................

Drive Tool Machines only 4--2..........................................

Chapter 5

Software and Hardware Axis Overtravel 5--1......

Software Axis Overtravel 5--1...........................................

CANCELLING SOFTWARE RANGE CHECKING 5--1.....................

Hardware Axis Overtravel 5--1..........................................

Chapter 6

G codes 6--1...................................

G codes 6--1.........................................................

Chapter 7

M codes 7--1...................................

M codes 7--1.........................................................

Table of Contents

M codes supported on Cincinnati Turning Centres 7--1.......................

Function Description of M Codes 7--2........................................

M00 PROGRAMME STOP (STOPS SPINDLE) 7--2.......................

M01 OPTIONAL PROGRAMME STOP (STOPS SPINDLE) 7--2.............

M02 END OF PROGRAMME 7--2......................................

M03 START SPINDLE CCW 7--3.......................................

M04 START SPINDLE CW 7--3........................................

M05 SPINDLE STOP 7--3.............................................

M08 FLOOD COOLANT START 7--3...................................

M09 COOLANT OFF 7--3.............................................

M13 STAR T SPINDLE COUNTER CLOCKWISE WITH COOLANT 7--3......

M14 STAR T SPINDLE CLOCKWISE WITH COOLANT 7--3................

M19 ORIENTED SPINDLE STOP 7--3...................................

M30 END OF PROGRAM AND REWIND 7--3............................

M34 PARTS CATCHER ADVANCE 7--4.................................

M35 PARTS CA TCHER RETRACT 7--4.................................

M44 RENISHAW TOOL SETTING ARM (TSA) UP 7--4....................

M45 RENISHAW TOOL SETTING ARM (TSA) DOWN 7--4.................

M46 FEEDRATE OVERRIDE DISABLE (100%) 7--4.......................

M47 FEEDRATE OVERRIDE ENABLE 7--4..............................

M48 SPINDLE SPEED OVERRIDE DISABLE (100%) 7--4..................

M49 SPINDLE SPEED OVERRIDE ENABLE 7--4.........................

M50 C--AXIS MODE OFF (Driven Tool Machines only) 7--5.................

M51 C--AXIS MODE ON (Driven Tool Machines only) 7--5..................

M52 C--AXIS BRAKE ON (In--Position Mode, Driven Tool FeatureDriven tool machines only)

7--5 M53 C--AXIS BRAKE ON-- (Interpolation Mode, Driven Tool Feature)Half pressure -- contour-

ing

(Driven tool machines only) 7--5......................................

M54 C--AXIS BRAKE OFF (Driven Tool Machines only) 7--6................

M61 BARFEED MACRO CALL 7-- 6....................................

M68 ADVANCE TAILSTOCK QUILL 7--6...............................

M69 RETRACT TAILSTOCK QUILL 7--6................................

M70 TO M73 CUSTOMER OUTPUTS (OPTIONAL) 7--6....................

M74 COLLET CHUCK MODE DISABLE 7--7.............................

M75 COLLET CHUCK MODE ENABLE 7--7.............................

M76 FORCE TURRET ROTATION CW 7-- 7..............................

M77 FORCE TURRET ROTATION CCW 7--7............................

M78 CHUCK OPEN 7--7..............................................

M79 CHUCK CLOSE 7--7.............................................

M80 BARFEED EJECT/RELOAD NEW BAR 7--7.........................

M86 BARFEED PRESSURE ON

(HYDRAFEED AND FEEDMASTER ONLY) 7--7.......................

M87 BARFEED PRESSURE OFF

(HYDRAFEED AND FEEDMASTER ONLY) 7--7.......................

M90 BARFEED MODE ON 7--7........................................

M91 BARFEED MODE OFF 7--7.......................................

M92 BARFEED ROTATION ON 7--8....................................

Table of Contents

M93 BARFEED ROTATION OFF 7--8...................................

M94 INCREMENT PARTS COUNTER 7--8...............................

M98 SUBROUTINE CALL 7--8.........................................

M99 END OF SUBROUTINE 7--8.......................................

Chapter 8

Spindle Functions 8--1.........................

Spindle Functions 8--1....................................................

Driven Tool Machines 8--1.................................................

Spindle Jog 8--2.........................................................

Chapter 9

Tooling Functions 9--1..........................

Tool Turret 9--1......................................................

Turret Indexes 9--1....................................................

Driven Tool Machines 9--1.................................................

T Word 9--2.........................................................

Force Turret CW and CCW 9--2.........................................

Tool Life Management 9--2.............................................

Chapter 10

Driven Tools 10--1...............................

Introduction 10--1......................................................

C--Axis Mode Enable/Disable 10--1.......................................

C--Axis Initialisation 10--1...............................................

C--Axis Positioning Mode 10--1..........................................

Programming Considerations 10--2........................................

C--Axis Interpolation Mode 10--5.........................................

Programming Considerations 10--5........................................

Chapter 11

Toolsetter 11--1.................................

Introduction 11--1......................................................

TSA 11--1............................................................

HPA 11--2............................................................

Macro Probing Routines 11--2...............................................

Manual Tool Setting 11--2...............................................

Auto Tool Setting -- TSA only 11--3.......................................

Operator and Programming Notes 11--3....................................

Tool Setting Arm Activation -- TSA 11--3......................................

M44 TSA Up 11--3....................................................

M45 TSA Down 11--3.................................................

Tool Setting Arm Down Pushbutton 11--4..................................

Tool Setting Arm Up Pushbutton 11--4.....................................

HPA -- Manual Toolsetting Arm 11--4.........................................

Fitting Arm 11--4......................................................

Table of Contents

Removing Arm 11--4...................................................

TSA/HPA Calibration 11--4..............................................

Stylus Alignment 11--5.....................................................

Stylus Alignment 11--5.................................................

Stylus Position 11--5...................................................

Control Options 11--5..................................................

Standard Calibration Data -- Base Number 522 11--5..........................

Adjusting the Software Back Off Distance 11--6..............................

Macro Parameters 11--6....................................................

Tool Nose Vector Hh 11--8...............................................

Calibration 11--9..........................................................

Manual Calibration -- Macro O9011 11--9......................................

Introduction 11--9......................................................

Description 11--9......................................................

Application 11--9......................................................

Format 11-- 9..........................................................

Macro Parameters 1 1--9.................................................

Outputs 11--10.........................................................

Manual Tool Setting -- Macro O9011 11--11.....................................

Description 11--11......................................................

Application 11--11......................................................

Format 11--11..........................................................

Macro Parameters 11--11.................................................

Outputs 11--11.........................................................

Set a Tool 11--11.......................................................

Broken Tool Check 11--12................................................

Auto Tool Setting -- Macro O9012 -- TSA Only 11--15.............................

Description 11--15......................................................

Application 11--15......................................................

Format 11-- 15..........................................................

Macro Parameters 11--15.................................................

Chapter 12

Parts Catcher 12--1..............................

Introduction 12--1......................................................

Operation 12--1........................................................

M34 Parts Catcher Advance 12--1........................................

M35 Parts Catcher Retract 12--1..........................................

Parts Catcher Advance Push Button 12--2...................................

Parts Catcher Retract Push Button 12--2....................................

Operator and Programming Notes 12--2....................................

Programming Example 12--2.............................................

Chapter 13

Barfeeder 13--1.................................

Introduction 13--1.........................................................

Table of Contents

Bar Preparation 13--1...................................................

M--Codes 13--1........................................................

Standard Barfeed Sequence for Multifeed Unit:-- 13--2.........................

Standard Barfeed Sequence for Hydrafeed and Feedmaster 13--3.................

Barfeed Spindle Rotation Speed Bits -- Keep Relay K Bits 13--4....................

Chapter 14

Reserved Macro Routines 14--1..................

Used Macro V ariables 14--1..............................................

Chapter 15

Connection to Data Input/Output Devices 15--1....

Connection to Data Input and Output Devices 15--1..............................

Input/Output Device and Code Number 15--2................................

Chapter 16

Diagnostics 16--1...............................

PMC Input Address Reference List 16--2.......................................

PMC Output Address Reference List 16--3.....................................

FANUC Operators Panel Connection Signals 16--4...............................

FANUC Operator Station 16--5..............................................

Self--Diagnostic Function 16--5...........................................

Status Display LED 16--5...............................................

Test Mode 16--5.......................................................

FANUC Operator Station Key/LED -- Diagnostic Address Table 16--6...............

Alarm Messages 16--7.....................................................

Operator Messages 16--73...................................................

Table of Contents

Fig. 1

Preferred Inch Lifting Eyebolts 1-- 7......................................

Fig. 2

Preferred Metric Lifting Eyebolts 1--8.....................................

Fig. 3

Eyebolt Loading 1--8..................................................

Fig. 4

Eyebolt I.D. Plates -- Inch and Metric 1--8..................................

Fig. 5

Instruction Plate -- Inch (Part Number 3375984) 1--8.........................

Fig. 6

Instruction Plate -- Metric (Part Number 3375983) 1--8.......................

Fig. 7

Hoist Ring 1--9.......................................................

Fig. 8

Hoist Ring Table 1--9..................................................

Fig. 9

Spreader Bar -- Typical 1--10.............................................

Fig. 10

Steel Alloy Chains 1--11................................................

Fig. 11

Wire Rope Slings 1--12.................................................

Fig. 12

Sling Load Angle Chart 1--13............................................

Fig. 13

“P” Type Lifting Hooks 1--14............................................

Fig. 14

“P” Type Lifting Hooks 1--14............................................

Fig. 15

“S” Hooks 1--15.......................................................

Fig. 16

“S” Hooks 1--15.......................................................

Fig. 17

“U” Type Lifting Hooks 1--16............................................

Fig. 18

“U” Lifting Hook Table 1--16............................................

Fig. 19

Safety Latch 1--17.....................................................

Fig. 20

Driven Head Tool Holder 1--26...........................................

Fig. 21

Hawk Turning Center 2--1..............................................

Fig. 22

Axis Orientation -- Hawk Turning Centre 2--6...............................

Fig. 23

Front View 2--9......................................................

Fig. 24

Left Side View 2--10...................................................

Fig. 25

Turning Capacity Chart -- Hawk 150 (VDI Tooling) 2--11......................

Fig. 26

Turning Capacity Chart -- Hawk 200 Machines (VDI Tooling) 2--12..............

1--26...................................................................

Table of Contents

Fig. 27

Turning Capacity Chart -- Hawk 250 Machines (VDI Tooling) 2--13..............

Fig. 28

Data Sheets -- Hawk 150 (VDI Tooling) 2--14................................

Fig. 29

Stroke -- Hawk 200 Machines (VDI Tooling) 2--15............................

Fig. 30

Stroke -- Hawk 250 Machines (VDI Tooling) 2--16............................

Fig. 31

Optional Standard Tooling Package -- Hawk 150 (VDI Tooling) 2--17.............

Fig. 32

Optional Standard Tooling Package -- Hawk 200/250 Machines (VDI Tooling) 2--18.

Fig. 33

Work Holding Options -- Hawk 150 2--19...................................

Fig. 34

Work Holding Options -- Hawk 200 2--20...................................

Fig. 35

Work Holding Options -- Hawk 200 2--21...................................

Fig. 36

Work Holding Options -- Hawk 250 2--22...................................

Fig. 37

Work Holding Options -- Hawk 250 (Continued| 2--23.........................

Fig. 38

Bar Feed Options -- Hawk 150 machines 2--24...............................

Fig. 39

Hawk 150 -- Spindle Power Characteristics 2--25.............................

Fig. 40

Hawk 200 -- Spindle Power Characteristics 2--25.............................

Fig. 41

Hawk 250 -- Spindle Power Characteristics 2--26.............................

Fig. 42

Machine Alignment And Program Points 2--27...............................

Fig. 43

Control Station Layout for:

-- Hawk Turning centres with fanuc 21i TA 3--1.............................

Fig. 44

Operators Control Panel 3--2............................................

Fig. 45

MTB Operators Control Panel 3--11.......................................

Fig. 46

Spindle Load Meter 3--11...............................................

Fig. 47

Main Spindle Chuck & Tailstock Pressure 3--15..............................

Fig. 48

Chuck Brake Pressure (Option) 3--15......................................

Fig. 49

Swarf Conveyor Control Panel 3--17.......................................

Fig. 49

12 Position Turret -- showing Rotation Directions 9--1........................

Fig. 51

Driven Tool Setup -- Positioning Mode 10--2................................

Fig. 52

C--Axis Positioning 10--2................................................

Table of Contents

Fig. 53

Canned Cycle -- Front Machining 10--3.....................................

Fig. 54

Canned Cycle -- Side Machining 10--4.....................................

Fig. 55

Driven Tool Setup -- Interpolation Mode 10--5...............................

Fig. 56

C--Axis Position Command 10--6.........................................

Fig. 57

Polar Co--ordinate Interpolation 10--7......................................

Fig. 58

Cylindrical Interpolation 10--8............................................

Fig. 58

Probe Configuration 11--1...............................................

Fig. 59

Probe Configuration 11--2...............................................

Fig. 60

Parts Catcher fitted to Operator Door 12--1..................................

Fig. 61

Operators Control Panel 16--6............................................

Chapter 1 Safety Precautions

Important

WARNING

Read related safety precautions before operating this machine. Failure to follow safety instructions may result in serious personal injury.

WARNING

Inordertoclearly showdetailsofthismachine,some covers, shields, guards, barriers,devices, ordoors have either been removed or shown in an ”open” position. All such protective components must be installedinpositionbefore operating this machine. Failure to follow this instruction may result in serious personal injury.

Thesesafety precautions for thisCINCINNATI machinehavebeenprepared to assist the operator, programmer and maintenancepersonnelin practicing good shop safety procedures.

Operator and maintenance personnel must read and understand these precautions completely before operating, setting up, running, orperforming maintenance on the machine.

Theseprecautions are to be used as aguidetosupplement safetyprecautions and warnings in the following:

a. All other manuals pertaining to the machine. b. Local, plant, and shop safety rules and codes. c. National safety laws and regulations.

Cincinnati Machine 91203597B001 Page 1--1

WARNING

Failure to follow instructions on this page may result in serious personal injury.

General Safety Instructions And Considerations

Personal Safety

Machineowners,operators,setupmen, maintenance, and servicepersonnel must be aware of the fact that constant day--to--day safety procedures are a vital part of their job. Accident prevention must be one of the principal objectives of the job regardless of what activity is involved.

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 -- complies with the following safety precautions and procedures when operating this machine.

Sudden movements, loud noises, horseplay, etc., must be avoided. These distractions may result in unsafe conditions for those working near the machinery.

Observe and follow safety instructions such as “NO SMOKING”, “High Voltage”, “DANGER”, etc., in your working area.

Accidents can occur that result in serious personal injury to yourself or othersduetoclothingandother articlesbecomingentangled in cutters,hand wheels, levers, or moving machineelements. The following suggestions, if followed, will help you to avoid such accidents: Neckties, scarfs, gloves (except as worn for protection when handling sharp edged cutting tools or rough, sharp or hot parts, see TOOL SAFETY) loose hanging clothing, and jewelry such as watches, rings, or necklaces must not be worn around moving machinery. Restrain long hair with a cap or net. Wear gloves only when handling rough, sharp, or hot parts.

Use safety protective equipment. Wear clean approved eye or face protection. Safety--toe shoes with slip--proof soles can help you avoid injury. Keep your protective equipment in good condition.

Neveroperateorservicethis equipmentifaffectedbyalcohol,drugsorother substances or conditions which decrease alertness or judgment.

Work Area Safety

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

Make sure your work area is free of hazardous obstructions and be aware of protruding machine members.

Returntoolsandsimilarequipmenttotheirproperstorageplaceimmediately after use. Keep work benches neat, orderly, and clean.

Report unsafe working conditions to your supervisor or safety department. Items such as: worn or broken flooring, ladders, and handrails, unstable or slippery platforms, or scaffolds must be reported and repaired before use. Do not use skids, work pieces, stock, machines, tote pans, and boxes as makeshift climbing aides.

Page 1--2

Cincinnati Machine 91203597B001

WARNING

Failure to follow instructions on this page may result in serious personal injury.

WARNING 1 CUTTING TOOLS

Use adequate hand protection at all times when handling sharp edged cutting tools.

Failure to follow this instruction may result in serious personal injury.

T ool Safety

Sharp edged cutting tools must be handled with gloves or a shop cloth. Inspect cutting tools before use and reject defective tools.

See WARNING 1. Remove hand tooling such as wrenches, measuring equipment, hammers,

and other miscellaneous parts from the machine immediately after usage.

Lifting And Carrying Safety

Contact supervision if you have any questions or are not sure about the proper procedures for lifting and carrying.

Before lifting or carrying an object, determine the weight and size by referringto such things as tags, shipping data, labels, marked information, or manuals.

Use power hoists or other mechanical lifting and carrying equipment for heavy, bulky,orhardto handleobjects. Use hookup methods recommended by your safety departmentand know the signals for safely directing a crane operator.

Never place any part of your body under a suspended load or move a suspended load over any part of another person’s body. Before lifting, be certain that you have a safe spot for depositing the load. Never work on a component while it is hanging from a crane or other lifting mechanism.

Ifindoubt as tothesizeortype ofliftingequipment,method, andprocedures for lifting, contact CincinnatiMachine beforeproceeding to liftthe machine or its components.

Always inspect slings, chains, hoists, and other lifting devices prior to use. Do not use lifting devices found to be defective or questionable.

Neverexceedthe safety ratedcapacity of cranes, hoists,slings, eyebolts,and other lifting equipment. F ollow, National and local, standards and instructions applicable to any lifting equipment you use.

Before inserting an eyebolt, be certain that both the eyebolt and the hole have the same size and type threads. To attain safe working loads, at least 90% of the threaded portion of a standard forged eyebolt must be engaged.

Cincinnati Machine 91203597B001 Page 1--3

WARNING

Installation And Relocation Safety

Before lifting the machine, consult the machine m anual or Cincinnati Machine for proper methods and procedures.

Failure to follow instructions on this page may result in serious personal injury.

An electrician must read and understand the electrical schematics prior to connectingthe machine to the power source. After connecting the machine, testallaspectsof the electrical system for proper functioning. Alwaysmake sure the machine is grounded properly. Place all selector switches in their OFF or neutral (disengaged) position. The doors of the main electrical cabinet must be closed and the main disconnect switch must be in the OFF position after the power source connection is complete.

Alwayslock the main disconnectdevice in the OFF position if the machine is left unattended, unless machine is part of an unmanned manufacturing system and in a production cycle.

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

Setup And Operation Safety

Readand understand all the safety instructions before setting up, operating, or servicing this machine. Assign only qualified personnel, instructed in safety and all machine functions, to operate or service this machine.

Operators and maintenancepersonnel must carefully read, understand, and fully comply with all machine mounted warning and instruction plates. Do notpaintover,alter,or defacethese platesorremovethemfromthemachine. Replace all plates which become illegible. Replacement plates can be purchased from Cincinnati Machine.

Safety guards, shields, barriers, covers, and protective devices must be connected or in place before operating t he machine.

All safety features, disengagements, and interlocks must be in place and functioningcorrectlypriorto operation of this equipment. Never bypass or wire around any safety device.

When setting up or adjusting a workpiece or fixture, be certain it is a safe distance away from the cutting tool. Always retract the workpiece a safe distance from the cutting tool when loading and unloading.

The spindle must be stopped beforeadjusting the coolant dischargenozzle. Neverbrakeor slow down moving machinerywith your hand or with some

makeshiftdevice.Neveruse machine power to remove a nut from anyshaft. The spindle and slides must be stopped when measuring work pieces, changing tools, or removing chips and grit. Remove chips and grit with a chip rake or brush, not with your hands.

Page 1--4

Cincinnati Machine 91203597B001

WARNING

Failure to follow instructions on this page may result in serious personal injury.

Keepall parts of your body offthe machinetable, table edge, outof the path of moving units, trip dogs, trip plungers, and out of the “machining area” during machining operations. Never lean on a machine or reach over or throughamachine-- you canbecomeentangledintoolingandothermoving elements or you may accidentally activate start buttons, feed controls, rapid traverse controls, power work holding control, or similar devices.

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 or grit which can cause breakage of tooling or machine elements.

Shut off power to the machinewhenleaving the operating area or at the end of your work period. Never leave the machine running unattended, unless it has beendesignedto do so. TurnthemasterdisconnectdevicetotheOFF position before cleaning the machineat the end of the working day or when guards or covers are removed that expose hazardous areas.

Maintenance Safety

See DANGER notice. Do not attempt to perform maintenanceon this machine until you read and

understand all the safety instructions. Assign only qualified service or maintenance personnel trained by

Cincinnati Machine, to perform maintenance and repair work on this machine. They should consult the service manual before attempting any service or repair work and when in doubt contact Cincinnati Machine. Use only Cincinnati Machine replacement parts; others may impairthe safety of the machine. Before performing maintenance or service work, Warning or Danger signs must be placed conspicuously about the machine. Before detachingcounterweights ordriving mechanisms, verticalsliding members must be blocked properly. See the Service Manual for proper dismantling procedures.

Before removing or opening any electrical enclosure, 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 theOFF position. If possible, post a sign at the disconnect switch indicating that maintenance is being performed.

Whenever maintenance is to be performed in an area away from the disconnectandthedisconnectisnotlocked,tagall start button stations with a “DO NOT START” tag. Adequate precautions, such as locks on circuit breakers, warning notices, or other equally effective means must be taken to prevent electrical equipment from being electrically activated when maintenance work is being performed.

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 are powered from a source away from the machine andcarry voltageeven when the machine’smaindisconnectdevice is turned to the OFF position.

Whenremovingelectrical equipment, place numberorlabeledtags on those wiresnot marked.Ifwiring, is replaced, besure it is of thesame type, length, size, and has the same current carrying capacity.

Cincinnati Machine 91203597B001 Page 1--5

WARNING

Failure to follow instructions on this page may result in serious personal injury.

Close and securely fasten all guards, shields, covers, plates, or doors before power is reconnected.

An electrical technician must analyze the electrical system to determine the possible use of power retaining devices such as capacitors. Such power retaining devices must be disconnected, discharged, or made safe before maintenance is performed.

Working space around electrical equipment must be clear of obstructions. Provide adequate illumination to allow for proper operation and maintenance.

DANGER

HIGH VOLTAGE Lethal voltages are presentin themagnetics and electrical

control cabinets whenthe MACHINE MAIN DISCONNECT is ’ON’. Current and voltage measurements should be attempted only by qualified electrical maintenance personnel.

Beforeworking on any electrical circuits, turn the machine Main Disconnect Device ’OFF’ and lock It.

Capacitors in the Servo Drives require up to 20 minutes to completely discharge. Always verify that discharge is complete using a known working and calibrated v oltmeter before commencing work on these units.

Unless expressly stated in applicable Cincinnati Machine documentation or by the appropriate Cincinnati Machine Field Service Representative, do NOT work with electrical power ’ON’. If such express statement of advice exists, working with electrical power ’ON’ should be performed by a Cincinnati Machine Field Service Representative. The customerandsubsequenttransfereesmustdeterminethat any other person performing work with electrical power ’ON’ is trained and technically qualified.

F AILURETO FOLLOW THIS INSTRUCTION MAYRESULTIN DEATH OR SERIOUS PERSONAL SHOCK INJURY.

Materials Used With This Product

Various materialsmaybe usedwiththisproduct.Beforeusing/mixing/diluting materials with this product, contact the manufacturer/authorized supplier of the material to determine that the material is suitable for the intended application andrequest a MaterialSafety DataSheet (MSDS) from the material manufacturer.

Page 1--6

Cincinnati Machine 91203597B001

NOTE

The information and tables contained in this article relate to Cincinnati Machine methods and standards. Consult National, Local and Plant Laws and Regulations regarding lifting practices.

WARNING

Before inserting an eyebolt, check to be certain that both the eyebolt and the hole have the same sizeandtypethreads. For example: M12withM12or .375 --16 with .375--16.

To attend safe working loads, at least 90% of the threaded portion of a standard forged eyebolt must be engaged.

Failure to follow this instruction may result in serious injury.

LIFTING DEVICES

GENERAL

The use of lifting devices is subject to certain hazards that cannot be met by mechanical means but only by the exercise of intelligence, care, and common sense. It is, therefore, essential to have competent and careful operators, physically and mentally fit, thoroughly trained to the safe operation of the equipment and the handling of the loads. Serious hazards are overloading, dropping or slipping of the load caused by improper hitching or slinging, standing or crawling under a load, swinging loads, obstruction to the free passage of the load, using equipment for a purpose or a manner for which it was not intended or designed..

EYEBOLTS

A straight lift is preferred when using eyebolts. An angular lift places additional stresses on an eyebolt, above that of the load to be hoisted.

Ifthesituationnecessitates an angularlift,the safe workingload for angular lifts shown in Fig. 1 and Fig. 2 should be used.

Whenmultiple eyeboltprovisionsaredesignedintoalift, it isrecommended (in most applications) that a spreader bar be used. (See Fig. 9 which illustrates a typical spreader bar arrangement.)

No greater stress should be allowed than that given under Safe Working Load in Fig. 1 and Fig. 2.

To obtain greatest strength from an eyebolt, it must fit reasonably tight in the hole with at least 90% of the threaded length engaged.

Eyebolts should never be welded or subjected to heat in excess of 900F [480 C].

Eyebolts should never be painted or otherwise coatedwhen used for lifting, as such coating will very likely cover up flaws.

Eyebolts should be routinely inspected for defects and if any defects are found,theyshouldbe destroyedbymelting,crushing,orcutting clearacross the eye.

STRAIGHT SHANK INCH (ANSI/ASME B18.15)

THREAD .375-- 16 .500-- 13 .625--11 1.000--8

SAFE WORKING LBS. [KG] LOAD

90 DEGREES 1000 1840 2940 7880

[453] [834] [1333] [3573]

60 DEGREES 375 805 1340 3670

[170] [365] [607] [1664]

30 DEGREES 200 470 805 2390

[90] [213] [365] [1083]

PART NUMBER 3449 870 21312 19489

IDENTIFICATION PLATE NUMBER 3338325 3338326 3338327 3338328

60

30

STRAIGHT SHANK INCH

90

Fig. 1

Preferred Inch Lifting Eyebolts

Cincinnati Machine 91203597B001 Page 1--7

SHOULDER METRIC (ISO 3266--1984)

THREAD M12 M16 M20 M30 SPOTDIAMETER 32mm 37mm 42mm 67 mm

1.25 in. 1.50 in. 1.65 in. 2.63 in.

SAFE WORKING [KILOGRAMS] LBS. LOAD

90 DEGREES [400] [630] [1000] [2500]

882 1389 2205 5512

45 DEGREES [100] [160] [250] [625]

220 352 551 1378

PART NUMBER 6014453--3 6014453--4 6014453--5 6014453--8

45



IDENTIFICATION PLATE NUMBER 3338329 3338330 3338331 3338332

Fig. 2

Preferred Metric Lifting Eyebolts

5 MAX.

LOAD

30 MIN.

YES

Fig. 3 Eyebolt Loading

6.00

THIS MACHINE HAS BEEN

MANUFACTURED TO UTILIZE

”INCH” THREAD LIFTING

3.00 DEVICES. ANY EXCEPTION

TO THIS WILL BE LABELED ADJACENT TO THE LIFT POINT.

.12

TYP.

NO 21 (.032) GAGEALUMINUM.-- NO. AL5052 ALLOY. ETCHEDAREAS TO BEBLACK BAKEDENAMEL.ETCHEDDEPTHTO BE .003 TO .005 INCHES

------ OR ------ NO. 21 (.032) GAGE

ALUMINUM WITH METALPHOTOPROCESS.ALL LETTERING TO BEHELVETICA MEDIUM.

.109 DIA.THRU 4PLACES

3375984

.08

.25

.12 R

Fig. 4 Eyebolt I.D. Plates -- Inch and Metric

3TYP.

NO 21 (.032) GAGE ALUMINUM.-- NO. AL 5052 ALLOY. ETCHED AREAS TO BE BLACK BAKED ENAMEL.ETCHED DEPTH TO BE .003 to .005 INCHES ------ OR ------ NO. 21 (.032) GAGE ALUMINUM

WITH METALPHOTOPROCESS. ALLLETTERING TOBE HELVETICA MEDIUM. SURFACE GRAIN TORUN PARALLEL TO LETTERING WITH SATINFINISH.

INCH

.375--16 UNC

THIS MACHINE HAS BEEN MANUFACTURED TO UTILIZE ”METRIC” THREAD LIFTING DEVICES. ANY EXCEPTION

TO THIS WILL BE LABELED ADJACENT TO THE LIFT POINT.

1.4 THRU--4

3TYP.

PLACES

3338325

SHOULDER METRIC

ISO METRIC

150

6.3

3375983

3338329

M12

Fig. 5 Instruction Plate -- Inch (Part Number 3375984)

Page 1--8

Fig. 6 Instruction Plate -- Metric (Part Number 3375983)

Cincinnati Machine 91203597B001

HOIST RINGS

PAR

T.N

PLATE

Hoist Rings are superior to eyebolts for angular lifting. Be certain the thread projection is in accordance with the manufacturer’s

recommendation. Do not recut any damaged threads on hoist rings. To obtain the safe working load, torque to the recommended values shown

in the table below.

Fig. 7 Hoist Ring

CM HOIST

RING

PARTNO.

3346225 1 .375--16 12.0 16.3 1000 450 866 390 707 318 500 225 5013055 001 3346225 2 .500--13 28.0 38 2500 1130 2165 975 1767 795 1250 562 5013055 002 3346225 3 .625--11 60.0 81.3 4000 1810 3464 1559 2828 1273 2000 900 5013055 003 3346225 4 1.000--8 230.0 312 10000 4500 8660 3897 7071 3182 5000 2250 5013055 004 3346225 6 M12X1.75 27.0 36.6 2204 991 1908 859 1558 701 1102 496 5013055 006 3346225 7 M16X2 59.0 80 3857 1736 3340 1503 2726 1227 1928 868 5013055 007 3346225 8 M20X2.5 100.0 136 4736 2132 4103 1846 3349 1507 2369 1066 5013055 008 3346225 9 M30X3.5 229.0 310 9257 4166 8016 3607 6544 2945 4628 2083 5013055 009

CM HOIST

RING

PARTNO.

3346225 1 .375--16 12.0 16.3 1000 450 1000 450 1000 450 5013055 001 3346225 2 .500--13 28.0 38 2500 1130 2500 1130 2500 1130 5013055 002 3346225 3 .625--11 60.0 81.3 4000 1810 4000 1810 4000 1810 5013055 003 3346225 4 1.000--8 230.0 312 10000 4500 10000 4500 10000 4500 5013055 004 3346225 6 M12X1.75 27.0 36 2204 991 2204 991 2204 991 5013055 006 3346225 7 M16X2 59.0 80 3857 1736 3857 1736 3857 1736 5013055 007 3346225 8 M20X2.5 100.0 136 4736 2132 4736 2132 4736 2132 5013055 008 3346225 9 M30X3.5 229.0 310 9257 4166 9257 4166 9257 4166 5013055 009

Fig. 8 Hoist Ring Table

THREAD

SIZE

THREAD

SIZE

THREAD TORQUE

Ft--Lb N--m Lb kg Lb kg Lb kg Lb kg

THREAD TORQUE

Ft--Lb N--m Lb kg Lb kg Lb kg Ft--Lb N--m

Observe all other safety precautions normally practiced on eyebolts.

90 _

MAX. WT

EACH RING

90 _

MAX. WT

EACH RING

60 _

MAX. WT

EACH RING

90

MAX. WT

EACH RING

45 _

MAX. WT

EACH RING

90

MAX. WT

EACH RING

30 _

MAX. WT

EACH RING

NOTE F=FORCE W=WEIGHT

CM IDENT. P

CM IDENT. PART. NO.

.xxx--xx

PLATE

RT. NO.

.xxx--xx

Cincinnati Machine 91203597B001 Page 1--9

SPREADER BARS AND LIFTING BEAMS

SPREADER

TO LOAD TO LOAD

Fig. 9 S

reader Bar -- T

ical

Spreader bars are used when multiple eyebolts are designed into a lift. Always observe the following safety precautions when using a spreader bar or lifting beam

Do not exceed the safe working load. Use the spreader or beam to handle parts or components only for which it

was designed. Inspect it before each use. Do not alter or weld anything to bar or beam. Store properly to avoid damage.

CHAIN

Selectachainwiththesuitablecharacteristics and capacityforthe load. See above. Always observe the following safety precautions.

Do not shorten chains with knots, bolts, or any non--approved method. Never use damaged chain. Hitch chain securely to the load. Pad sharp cornerswith materialof sufficientstrength to withstand load and

protect chain.

Page 1--10

Cincinnati Machine 91203597B001

DOUBLE SLING CHAINS

SIZE OF

CHAIN

9/32 in. lbs. 3 250 5 625 4 600 3 250 8 400 6 900 4 875 8400 6900 4 875

.7.2 mm kg. 1 475 2 550 2 085 1 475 3 810 3 130 2 210 3 810 3 130 2 210

3/8 in. lbs. 6 600 11 400 9 300 6 600 17 100 13 950 9 900 17 100 13 950 9 900

9.5 mm kg. 2 995 5 170 4 220 2 995 7 750 6 330 4 490 7750 6 330 4 490 1/2 in. lbs. 11 250 19 700 15 900 11 250 29 250 23 850 16 875 29 250 23 850 16 875

712.7 mm kg. 5 100 8 845 7 210 5 100 13 270 10 820 7650 13 270 10 820 7650 5/8 in. lbs. 16 500 28 600 23 300 16 500 42 900 34 950 24 750 42 900 34 950 24 750

15.9 mm kg. 7 480 12 970 10 570 7 480 19 460 15 850 11 230 19 460 15 850 11 230 3/4 in. lbs. 23 000 39 800 32 500 23 000 59 700 48 750 34 500 59 700 48 700 34 500

19.1 mm kg. 10 430 18 050 14 740 10 430 27 080 22 110 15 650 27 080 22 110 15 650 7/8 in. lbs. 28 750 49 800 40 700 28 750 74 700 61 050 43 125 74 700 61 050 43 125

22.6 mm kg. 13 040 22 590 18 460 13 040 33 880 27 690 19 560 33 880 27 690 19 560 1in. lbs. 38 750 67 100 54 800 38 750 100 650 82 200 58 125 100 660 82 200 58 125

25.4 mm kg. 17 580 30 440 24 860 17 580 45 650 37 290 26 260 45 650 37 290 26 260

1 1/4 in. lbs. 57 500 99 600 81 300 57 500 149 400 121 950 86 250 149 400 121 950 86 250

31.8 mm kg. 26 080 45 180 36 880 26 080 67 770 55 320 39 120 67 770 55 320 39 120 1 1/2 in. lbs. 80 000 138 500 113 000 80 000

38.1 mm kg. 36 290 62 820 51 260 36 290

1 3/4 in. lbs. 100 000 73 200 41 000 100 000

44.5 mm kg. 45 360 78 560 63 960 45 360 2in. lbs. 130 000 225 000 183 000 130 000

50.8 mm kg. 26 750 102 060 83 000 26 750

SINGLE

CHAIN



TYPE D

60 45 30

TRIPLE SLING CHAINS

TYPE T

60 45 30

QUAD SLING CHAINS

TYPE Q

60 45 30

Fig. 10 Steel Alloy Chains

Keep hands and fingers from between the chain and load. Avoidshockloading-- particularlywhenworkingat temperaturesbelow40

F[4 C]. Never pull chain from under load when load is resting on chain. Correct kinks and twisting in chain before lifting. Lift from center of hooks. Avoid lifting from the point. Assurethatloadisfreeto move beforelifting.Keepclearof all obstructions. When using a basket hitch, balance load and assure that chain legs contain

or support load from the sides above the center of gravity. Storechainsin an area where they will notbe subject to mechanicaldamage

or corrosive action.

Cincinnati Machine 91203597B001 Page 1--11

CABLE SLINGS

Select the appropriate size wire rope and hitch. See Table below.

CABLE

SIZE

1/4 in. lbs. 980 740 1400 1700 1400 980

6.4 mm kg. 445 335 635 770 635 445 1/2 in. lbs. 3600 2800 5200 6400 5200 3600

712.7 mm kg. 1630 1270 2360 2900 2360 1630 3/4 in. lbs. 7800 5800 11100 13600 11100 7800

19.1 mm kg. 3450 2630 5035 6170 5035 3450 1in. lbs. 13400 1000 18800 22000 18800 13400

25.4 mm kg. 6080 4540 8530 9980 8530 6080 1 1/4 in. lbs. 19600 14800 28000 34000 28000 19600

31.8 mm kg. 8890 6710 12700 15420 12700 6710 1 1/2 in. lbs. 28000 20000 40000 48000 40000 28000

38.1 mm kg. 12700 9070 18140 21770 18140 12700 1 3/4 in. lbs. 38000 28000 54000 66000 54000 38000

44.5 mm kg. 17240 12700 24490 29940 24490 17240

2in. lbs. 50000 36000 70000 86000 70000 50000

50.8 mm kg. 22680 16330 31750 39000 31750 22680

Fig. 11 Wire Rope Slings

ESTIMATED RATINGCA-

PACITY

(For Exact

Rating Check

Sling Tag)

VERTICAL

CHOKER

HITCH

BASKET

HITCH

60 45

30

Guide loads with a tag line when practical. When using multiple leg sling, select longest one possible. Examine for damaged or worn area. Attach securely to load. Pad sharp corners to protect wire rope. Center load in the base (bowl) of the hook to prevent hook point loading. Do not kink, twist, or loop legs. Keep hands and fingers from between wire rope and load. Stand clear of attached load. Start lift slowly to avoid shock injury. Do not pull wire rope from under a load when the load is resting on it. Do not shorten sling by knotting, by wire ropeclips, or by any other means. Do not inspect wire rope by passing barehands over the body.Brokenwire,

if present, may puncture the hands. Keep wire rope well--lubricated to prevent corrosion.

Page 1--12

Use gloves at all times when handling.

Cincinnati Machine 91203597B001

SYNTHETIC MATERIAL SLINGS

Select the sling with the suitable characteristics and capability for the load and environment. See Fig. 12.

AS THE SLING TO LOAD ANGLE DECREASES, SO DOES THE RATED CAPACITY OF A SLING.

SLING--TO--LOAD ANGLE IS ALWAYS THE ANGLE BETWEEN THE SLING LEG AND THE HORIZONTALSURFACE.

SLING

LOAD

ANGLE

Fig. 12 Sling Load Angle Chart

USE THIS CHART FOR ALL TYPE SLINGS; ROPE, CHAIN, OR NYLON.

90

75

60

45

30

RATEDSLING CAPACITY--ONE LEG

SLING

LIFTING

EFFICIENCY

100.0 %

96.6 %

86.6 %

70.7 %

50.0 %

If Sling Ca-

pacity

at 90

 is...

(LB. [KG])

1000

[454

]

1000

[454

]

1000

[454

]

1000

[454

]

1000

[454

]

Then Actual

Sling Capacity

is ...

(LB. [KG])

1000

[454

]

968

[439

]

866

[390

]

707

[320

]

500

[225

]

When using a choker hitch, the sling shall be long enough to assure that the choking action is on the webbing.

Slings used in a basket hitch shall have the load balanced. Do not drag slings over the floor or any abrasive surface. Do not twist or tie knots in slings. Never pull sling from load when the load is resting on it. Protect sling from sharp corners and abrasive surfaces. Do not drop slings. Store slings in an area where they will not be subject to mechanical or

chemical damage. Do not use where acid conditions exist. Do not use polyester and polypropylene slings where caustic conditions

exist. Do not use polyester and nylon slings at temperatures in excess of 180

F nor polypropylene slings at temperatures in excess of 200 F. Do not use aluminum fittings where caustic conditions exist.

Cincinnati Machine 91203597B001 Page 1--13

P TYPE HOOKS

P type hooks are a proprietary design and should be considered for heavy (machine and unit) lifts.

Fig. 14 gives dimensional data, safe working loads andscrewtorquevalues for P type hooks.

The use of these hooks must be shown on the assembly drawing, listed in the Bill of Material and shown in the lifting section of the ServiceManual.

Fig. 13 “P” Type Lifting Hooks

PART

NO.

402517 1800 [818] 2.00 9.75 4.50 3.00 2.50 -- -- -- 2415 2 160 217 296513 2500 [1136] 1.75 10.63 4.00 2.50 4.00 -- -- -- 2415 2 160 217 296514 3500 [1590] 2.00 12.25 4.50 3.00 2.50 5.00 2415 3 160 217 402335 5000 [2273] 2.25 12.25 4.50 3.00 5.00 -- -- -- 180139 2 370 502 296515 8000 [3636] 2.25 15.75 4.50 3.00 4.00 7.88 180139 3 370 502

Fig. 14 “P” Type Lifting Hooks

LIFTING SCREW SCREW

CAPACITY

LBS. [KG]

A B C D E F SCREW NO. QTY.

INCH INCH INCH INCH INCH INCH

WHEN DESIGNING METRIC SIZES SEE THE CURRENT LIFTING MANUAL

TORQUE TORQUE

LB./FT. N--m

S HOOKS

The use of S hooks in conjunction with some of the other lifting devices dictates additional safety rules which must always be practiced.

Never use more than one S hook in a single chain link or hook. Inspect the S hook before each use and if damaged destroy by cutting into

two pieces. Neverexceed the safe workingload which should be stamped on each hook. Do not paint, weld, or expose an S hook to high heat.

Page 1--14

Cincinnati Machine 91203597B001

STAMPTO INDICATE ALLOY

Do not use when either or both S hooks are opened more than 15% of the normal throat opening or twisted more than 10 from the plane of the unbent hook.

R(REF.)

STAMPWORKING LOAD LIMIT WITHLOW STRESS CHARACTERS PER NUCLEAR AMERICAN SOCIETY OF MECHANICAL ENGINEERS CODE

SECTION III,DIV. 1, PARAGRAPH NA--3766.6 (2)

STAMP MFGR. NAME OR TRADEMARK FOR IDENTIFICATION

Fig. 15 “S” Hooks

PARTNO.

MAX. WORKING

LOAD

LBS. KG

MANUFACTURER AND

CODE NUMBER

ALL DIMENSIONS IN

INCHES

(See Fig 16.)

S--HOOK

WEIGHT

A B C R LBS.

3590535--5 650 294 CM Chain 562250 0.500 7.50 2.00 1.00 0.80

Amer. Chain & Cable 5933--00800 0.500 5.50 1.50 0.75 0.63

3590535--7 1 015 460 CM Chain 562262 0.625 9.00 2.50 1.25 1.60

Amer. Chain & Cable 5933--01000 0.625 7.00 1.88 0.94 1.30

3590535--8 1 465 664 CM Chain 562275 0.750 10.50 3.00 1.50 2.60

Amer. Chain & Cable 5933--01200 0.750 8.25 2.25 1.12 2.10

3590535--9 1 990 902 CM Chain 562287 0.875 12.00 3.50 1.75 4.20

Amer. Chain & Cable 5933--01400 0.875 9.62 2.62 1.31 3.40

3590535--10 2 600 1179 CM Chain 562300 1.000 13.00 4.00 2.00 6.00

Amer. Chain & Cable 5933--01600 1.000 11.00 3.00 1.50 5.10

3590535--12 3 290 1492 CM Chain 562310--B 1.125 15.00 4.50 2.25 8.70

Amer. Chain & Cable 5933--01800 1.125 12.12 3.38 1.69 7.00

3590535--14 4 065 1843 CM Chain 562325--B 1.250 16.00 5.00 2.50 11.70

Amer. Chain & Cable 5933--02000 1.250 13.75 3.75 1.88 10.00

3590535--15 4 915 2229 CM Chain 562337--B 1.375 17.00 5.50 2.75 15.40

Amer. Chain & Cable 5933--02200 1.375 14.88 4.12 2.06 13.00

3590535--16 5 850 2653 CM Chain 562350--B 1.500 18.00 6.00 3.00 19.50

Amer. Chain & Cable 5933--02400 1.500 16.50 4.50 2.25 17.50 3590535--18 9 500 4309 Amer. Chain & Cable 5933--02800 1.750 19.25 5.25 2.62 28.00 3590535--20 12 500 5669 Amer. Chain & Cable 5933--03200 2.000 22.00 6.00 6.00 41.00 3590535--25 19 000 8618 Amer. Chain & Cable 5933--04000 2.500 27.50 7.50 9.75 79.00

Fig. 16 “S” Hooks

Cincinnati Machine 91203597B001 Page 1--15

U TYPE HOOKS

U type hooks are a proprietary design and should be considered for heavy (machine and unit) lifts.

Fig. 17 and Fig. 18 give dimensional data, safe working loads and screw torque values for U type hooks.

The use of these hooks must be shown on the assembly drawing, listed in the Bill of Material and shown in the lifting section of the ServiceManual.

Fig. 17 “U” Type Lifting Hooks

LIFTING SCREW SCREW

PARTNO.

303427 1 500 [680} 2.75 4.00 2.25 1.25 3248 2 45 61

303429 3 500 [1587] 3.25 4.50 2.50 1.50 2400 2 90 122 301269 6 000 [2720] 4.00 6.00 3.75 2.00 2415 2 160 217 301270 8 000 [3600} 5.00 6.50 3.88 2.25 180139 2 570 502 301271 12 000 [5442] 6.00 8.00 4.50 2.50 308196---3 2 735 997 301272 16 000 [7256] 7.00 9.50 5.30 3.00 308197---4 2 1290 1749 311105 25 000 [11 337] 7.00 14.25 6.00 3.50 308197---4 2 1290 1749

990819 1 500 [680] 75 107 60 32.0 1234074 2 41 30

3988405 3 000 [1360] 90 120 65 38.0 1234100 2 108 80 3990821 6 000 [2720] 105 155 95 50.0 1400264 2 230 170

5024235 8 000 [3600] 130 180 103 57.2 1400400 2 407 300 5025776 14 000 [6500] 170 250 133 76.2 6010088--3 2 1356 1000 5026032 22 500 [10 200] 300/180 380 159 88.9 6010088--3 4 1356 1000

CAPACITY

LB. [KG] in in in in SCREW NO. QTY. LB./FT. N--m

LB. [KG] mm mm mm mm SCREW NO. QTY. N--m LB./FT.

A B C D

TORQUE TORQUE

Fig. 18 “U” Lifting Hook Table

Page 1--16

Cincinnati Machine 91203597B001

GENERAL SAFETY LIFTING INFORMATION

Allhooks or cranes or any othertype lifting device should be equippedwith a safety latch (see Fig. 19) similar to the one manufactured by the Harrington Co., Plymouth Meeting, Pennsylvania.

Fig. 19 Safety Latch

Illustrations or descriptions of any special lifting devices or techniques required for servicing components of a specific machine are found in the section dealing with the particular component.

Always contact the nearest Cincinnati Machine representative if there are any questions regarding the lifting of any machine components.

Cincinnati Machine 91203597B001 Page 1--17

WARNING CUTTING FLUIDS

When soluble coolants areused, it is important to ensure that recommended concentration levels are maintained.

Fluids Used With Machine Tools

General Considerations

Various fluid products, such as cutting fluids, lubricants, etc., are used with this machine tool. The correct type and quantity is identified by instruction platesonthemachineand/or writteninstructions inthesuppliedmanual(s).

Before using fluids or related products not specifically approved or recommended with this machine tool, the owner/user should contact the authorized supplier, closest Cincinnati Machine regional field office for assistance in determining if the product is suitable for the particular application.

Lubricants

Only those lubricants (oils and greases) tested and approved by Cincinnati Machine, should be used in Cincinnati machine tools. For information concerning latest lubricants manual, contact Cincinnati Machine service department.

Cutting Fluids

Before filling the machine, ensure that the product is suitable for the application. Frequently, check for storage, tank unit or hose leaks.

Watermixedfluids thatcontainemulsifiersmustbeprotectedfromfreezing. Cutting fluid products should be tailored to each machine tool application

and workpiece requirement for maximum efficiency. See WARNING.

Failure to follow this Instruction can cause corrosion of safety critical parts, resulting in machine damage and/or personal injury.

For assistance in determining the correct cutting fluid, contact nearest Cincinnati Machine Service Department.

Sources Of Information -- USA

Beforeusinganyfluidproductwiththismachinetool,theowner/usershould request a Technical Data Product Safety Sheet (for example: OSHA Form 20 or a similar technical data information sheet) f rom the product manufacturer. This data should include the following:

Fire and Explosion Hazard Chemical and Trade Name Data Acute Toxicity Properties Spill or Leak Procedures Hazardous Ingredients Special Protective Information Physical Data Special Precautions Recommended Dilutions

Page 1--18

Cincinnati Machine 91203597B001

Listed below are some other sources which can be contacted to obtain additional up--to--date information concerning the safe use, handling, storage and disposal of products, materials, chemicals or substances.

Occupational Safety and Health Resource Conservation and Act (OSHA) Public Law Recovery Act (RCRA) Public Law

Department of Transportation National Institute for (DOT) Hazard Classification— Occupational Safety and The Transportation Safety Act Health (NIOSH)

Product Safety Data Sheet Cincinnati Machine Toxic Substances Control Act P.O. Box 9013 (TSCA) Public Law Cincinnati, Ohio 45209

Federal Insecticide, Fungicide and American National Standards Rodenticide Act (FIFRA) Public Institute, Inc. (ANSI) Law

American Conference of

Environmental Protection Agency Governmental Industrial

Hygienists, Threshold Limit

Federal Hazardous Substances Act Values

Clean Water Act

After receiving the data, analyze and perform the necessary procedures to assure the safe handling, storage, use and disposal of the product. Emergency/FirstAidproceduresand training should be readilyavailableto personnelhandlingor usingproductswhichmaybehazardous(flammable), harmful (toxic) and/or reactive (unstable)

The owner/user should become familiar with and keep informed on all regulated materials or substances. Copies of the latest regulated material may be obtained from agencies, such as NIOSH, Registry of Toxic Effects for Chemical Substances, U.S. Department of Health Education and Welfare, Public Health Service, Center for Disease Control, and the National Institute for Occupational Safety and Health.

Usage Information

Products must not be mixed with other products unless permission and/or instructionshavebeengrantedbythemanufacturer(s).Productconcentrates must be mixed and diluted exactly as instructed by the manufacturer for a particular approved application.

All product CAUTION, WARNING and DANGER labels, tags and printed instructions accompanying the products must be read and followed This instruction shall remain with the product at all times. Additional product instruction labels, signs, etc., should be acquired and displayed with concentrates that are purchased in bulk and then dispensed in small or diluted quantities

Cincinnati Machine 91203597B001 Page 1--19

Cutting Fluids -- Preventative Maintenance

SeeCautions1and2

CAUTION 1 COOLANTS

It is not recommended that neat mineral oils be used as a cutting fluid for this machine.

Failure to heed this warning could seriously impair the efficiency of both the coolant and swarf removal systems.

CAUTION 2 COOLANTS

It is not recommended that coolants having a high demulsification factor, be used with this machine.

Such coolants must be checked for compatability withtheoils and greasesrecommended for use with this machine.

Failure to follow this instruction can lead to lubrication problems, resulting in damage to the machine.

Cutting fluids are designed to cool and lubricate t he tool tip while in a cut. There are many types of cutting fluids, some of which may cause various problems on a machining center tool, such as corrosion, bacteria build--up, solid formations of chips and cutting debris, etc. if incorrectly applied.

The user should be aware of these potential problems, and guard against them.

Two types of cutting fluids can be used on this machine, semi--synthetics, andemulsions. Eachhasitsownadvantagesand disadvantagesandtheuser should consider all of them when making a product selection.

Water Quality

Water is the major ingredient in a water--basedcutting fluid. Its importance in product performance cannot be ignored.

Corrosion, residue, scum, rancidity, foam, excess concentrate use, in fact almostany cutting fluid performance problem may be causedbythequality of the water used in making the mix.

Too Soft

Whenthemixwaterhasatotalhardnessoflessthat75ppm,thecuttingfluid may foam -- especiallyinapplicationswherethereisagitation. Foamcauses problems when it overflows the reservoir, the m achining center,the return trenches,etc. Foammayalsointerferewithsettlingtypeseparators,obscure the workpiece, and diminish t he cooling capacity of a water--based cutting fluid. Generally, all products foam more readily in soft water.

Too Hard

Hard water, when combined with some water--based cutting fluids, promotes the formation of insoluble soaps. The dissolved minerals in the water combine with anionic emulsifiers in the cutting fluid concentrate to form these insoluble compounds that appear as a scum in the mix. Such scum coats the sides of the reservoir, clogs the pipes and f ilters, covers machining centers with a sticky residue, and may cause sticking gauges, pushbuttons, selector switches, and other similar devices.

Page 1--20

Hard water can promote corrosion of machine components and should always be eliminated. De--ionized water will help deal with the problem of hard water, provided advice has been sought.

Cleaning The Coolant Reservoir

The system requires periodic attention and servicing. The reservoir should be drained and cleaned periodically to remove sediments and prevent conditions that lead to deterioration of the coolant. The reservoir can be cleaned by removing the used fluid before adding and circulating a commercial cleaner or as required by adding a suitable cleaner to the used coolant in the machining center during a shut--down period while the machineis cycling. Specificcleaning procedures should be suppliedonthe label of each cleaning product.

Cincinnati Machine 91203597B001

Lifespan

The lifespan of cutting fluids varies widely and depends on many factors. Thebasictypeofcoolant,thehardnessofthe water,thetypesofmetalinthe coolant tank, the cleanliness of the system, and the amount of tramp oil in the fluid, all are factors that affect lifespan.

Tramp Oil

Tramp oils need to be controlled. Tramp oils in the coolant mix cause a varying degree of degradation of the coolant quality.

Minimizetheleakageofoilsintothesystem through proper maintenance of sealsandlubricantsystems. If excess quantities of oils leak into the system, the metalworking fluid performance can be reduced. Lubricating and hydraulic oils contain food for bacteria. They may also blanket the fluid, excluding air, and thereby provide ideal conditions for the growth of odor producing bacteria. If allowed to build up, extraneous oil causes smoking and increases residue around the machining center area.

The elimination of tramp oils is even more important if chemical cutting fluids are used. Hydraulic oil is a contaminant that must be kept out of the cutting fluid. Hydraulic oils, and particularly some of the additives

formulatedintothem,cancauseseriousdamagetothemachinetooland cutting fluid when mixed with water.

Iftrampoilbuild--upshouldbecomeaproblem,variouscommercialdevices are available to remove it.

Filtering

The cleanliness of the coolant is very important in regards to the reliability of the various coolant valves, tubing, etc. This Machining Center is equipped with a coolant filter system. It is good practice to ensure that any filters are kept in good operating condition.

Rust Prevention

When a machining center tool is sitting idle for a period, the possibility of corrosionincreases. There arecertainprecautions that the user must taketo prevent damage to the precision ground surfaces on this machine tool. Under certain conditions, damage can occur within as little time as a day or two; therefore, it is important that proper precautions be carried out.

Ifthemachiningcenterisgoing to sit idle foraperiod,itisimportanttowipe all the coolant off the slideways and then protect them with a good rust--preventive. On the horizontal axes of the machining center, it may be necessarytoruntheslidesbackandforthanumberoftimes,wipingtheways each time, until no coolant is seen originating from under the slide.

After the coolant is clear from under the slide, spray the rust--preventive on thewaysandmovetheslideagain,takingtherust--preventivebackunderthe slide.

Cincinnati Machine 91203597B001 Page 1--21

WARNING 1

Donotexpose PCBoardsto electro--static discharge, as intermittent board failures may occur and cause erratic machine operation. Failure to follow this instruction may result in personal injury.

WARNING 2

Qualified electrical personnel must disconnect all electrical power before printed circuit boards are replaced. Failure to follow this instruction may result in personal injury.

WARNING 3

Do not set PC Boards in styrofoam, waxed, rubber, plastic or other high rated non--conductive (dielectric) materials. Failure to follow this instruction may result in personal injury.

Printed Circuit Board Handling Instructions

General

All integrated circuits are susceptible to electro--static discharge damage. Because of this condition, special procedures must be used when handling circuit boards containing integrated circuits, even though there is no completelyfoolproof system of protecting integrated circuits. Metal oxide semi--conductor (MOS) assemblies manufactured byVickers Electronic Systems Division Incorporatedaresupplied with acautionsticker. Referto the sticker and the information concerning cautions and warnings in the supplied literature.

NOTE: It is important to emphasize that electro--static discharge to a PC

Board may not completely destroy an assembly component, but severely de--grade this component to a point where intermittent failures may occur .

If static discharge occurs at sufficient magnitude (2kV or greater) damage or degradation will usually occur i f recommended handling procedures are notused. Personnelhandling equipment in a lowhumidity environmentcan generate static potentials in excess of 10kV. Do not touch any integrated circuit assemblies at the pins, leads or edge connectors, since most damage is done at these points. See WARNING 1.

Recommended Handling Procedure

Before removing or replacing any PC Board, a qualified technician must disconnect all electrical power, including battery back--up devices. Refer to the machine dedicated electrical diagrams. See WARNING 2.

A recommended procedure before handling printed circuit boards is as follows:

1. Attach a grounded ”wrist strap” in contact with the skin. This strap should have a resistor value of 1 megohm (1/2 watt) in series with the person and grounded to leak off electro--static discharge.

2. When working with static control devices (for example: a bag or pad), touch the device with your grounded hand. This action will place you and the static control device assembly at the same electro--static potential.

Store and transport the printed circuit boards in static control bags. Use ”shortingbars”or conductive foam materials. Donot use a suspected static damaged printed circuit board. See WARNING 3.

Below are examples of electro--static caution symbols which may appear in areas of concern (for example: packing, shipping or receiving). These symbols signify that the ”Recommended Handling Procedures” must be used and/or follow any special supplied instruction.

Page 1--22

Cincinnati Machine 91203597B001

Safety Features

WARNING 1

PERIMETER GUARDING It is imperative that this

guarding is kept intact and in place at all times during normal operation of the machine.

In such cases where the part of the guarding has tobe removed formaintenance purposes, the guardingMUSTbereplaced before the machine is allowed to go back into normal operation.

Failure to follow this instruction may result in serious personal injury.

WARNING 2

Perimeter Guarding

A complete set of perimeter guards is supplied and fitted to this machine. See WARNING 1.

OPERATOR ACCESS TO THE MACHINE is gained at the following point(s):--

1. Operator Door -- for loading and unloading components and for setting up purposes.

Operator Sliding Door(s)

See WARNING 2. With the door(s) closed and machine power on, a safety switch is actuated

that allows automatic machine movements to be executed.

OPERATOR DOOR POWER LOSS

If machine power is lost while the door is in its closed position, it will re main latched in that position until power is re--applied.

The door can be opened from the inside using the special key attached to the underside of the SHOT BOLTbody. Do not attempt tooperate the machine with this door open.

Failure to follow this instruction may result in serious personal injury.

It is not possible to open the operator door/s while the machine is in automatic cycle, due to the latching mechanism of t he switch.

With the door(s) open and machine power on, the following conditions apply:

With the door(s) open and machine power on, the following functions are available under HOLD TO RUN control.

S Spindle rotation is inhibited. S Power feed of the X and Z axes are limited to 2m/min maximum.

The following functions are also available for selection.

1. Coolant Start.

2. Tailstock quill movement.

3. Spindle chuck open/close.

Cincinnati Machine 91203597B001 Page 1--23

CAUTION Emergency Stop

Actuatingthisbuttonwiththe machine in a cutting cycle may damage cutting tools and work pieces.

Failure to follow this instruction may resultin damageto equipment.

DANGER

The ELECTRICAL ISOLATION switch does NOT isolate the incoming supply to the electrical cabinet or the supply to the transformer unit. Use extremecare when working near the power inputleads.Severeshockinjury can result if the leads are touched.

Feed Hold Push Button

Provides logical and safe interruption of the active machine cycle when actuated.

Emergency Stop Push Button

See CAUTION. Providesfastestpractical elimination of machinemovements(spindle,axes

and mechanisms, etc.).

Electrical Isolation Device (Main Disconnect Switch)

A lockable isolation switch is provided on the main electrical cabinet. See DANGER.

It should also be noted that it may take up to 20 minutes to discharge completely the capacitors mounted in the servo drives.

Air Supply Isolation Valve

A pneumatic isolation valve is required to be provided by the customer to allow for the removal of air power from the machine.

Metric Lifting Points

This machine has been manufactured to utilise “METRIC” thread lifting devices. Any exception to this will be labelled adjacent to the lift point.

Failure to follow this instruction may result in death or serious personal injury.

Page 1--24

Cincinnati Machine 91203597B001

WARNING 1

Failure to follow instructions on this page may result in serious personal injury.

Machine Related Safety And Usage Notes

Axis Overtravel Condition

Care should be taken when power feeding an axis out of axis overtravel condition,to ensurethatthedirectionselectedbrings the axisawayfromthe overtravelcondition. Ifthewrongdirectionisselecteditispossible to drive theaxisfurtherintoovertravelwhich could result in damageto themachine.

Safe Operation Of Lathe Chucks

Ensure the chuck is of good condition as damage may impede its safe function especialy at high speeds.

Maximum operating speeds for chucks are for guidance only and attention should be made to the size and shape of the workpiece and t ooling.

The influence of centrifugal force may result in the work piece becoming insucurelygrippedundercertainconditions. Asthefactorsvarywidelywith each particular application we are unable to provide specific figures for general use, but the following should be observed;

1. Speed for an application

2. Weight and type of jaws if non--standard

WARNING 2

Inadequately supported bar--stock protruding from the headstock may cause whipping. Ensure the material is correctly supported at all times.

3. Radius at which jaws are operating

4. Condition of chuck

5. State of balance

6. Magnitude of the cutting forces

7. Clamping force applied to the work--piece

When a manual chuck or fixture is used, remove the clamping handle from the chuck or fixture after tightening and before operating/rotating the spindle or moving the axes.

Work Holding Devices

Always support the work--piece using the correct work holding device, eg. chucks, steadrests and centres.

Care should be taken to support work--piece when clamping/unclamping. Safe maximum speedof rotation should be observed, as determined by the

work holding device manufacturer. Bar stock protruding from the end of the headstock should be adequately

supported at all times. See Warning 2.

Failure to follow this instruction may result in serious personal injury.

Cincinnati Machine 91203597B001 Page 1--25

WARNING

Failure to follow instructions on this page may result in serious personal injury.

General Operation

Loosentool holder/cutting tool bolts gradually. Keep stablefooting and do not overtighten these bolts. Check with the manufacture for proper re--torquing values.

Securelytightenalltoolholders,toolschuckjaws. Balancingof theseitems may be necessary. Check with the manufacture for proper re--torquing values.

Always use two spanners to lock cutting tools into a ’Driven Head’ tool holder. One spanner is located on the rotating spindle unit within the head whilst the other locates on the spindle locknut, see Fig. 20.

Fig. 20 Driven Head Tool Holder

CAUTION

Attemptingto lock orunlock a tool in a Driven Head tool holder whilst it is mounted in a turret stationmay causeexcessive torsional strain in the spindle drive mechanism.

Failure to follow this instruction could result in serious damage to the drive tang on the Driven Head tool holder and drive mechanism.

Never attempt to lock or unlock a tool in a Driven Head when the head is mounted in a tool station on the turret. See CAUTION.

Always use a bench m ounted propriety Tightening Fixture to lock and unlockatool from a Driven Headtoolholder. Fordetails,seemanufacturers catalogue.

Atoolholderoraplasticblankingplugshouldbepresentineachoftheturret tool stations. Blanking plugs (shown in Figure 32) are recommended to occupyturretstationsnotinusetopreventtheingressswarfand coolant, etc. See manufacturers catalogue.

Lower the spindle s peed when changing the speed range while the spindle is rotating.

Do not insert bar stock into a rotating spindle. The bar stock length should be shorter than the spindle‘s length.

Bar stock must be straight in order to prevent vibration. Do not attempt to remove chips if t he spindle, turret or any machine

component is in motion.

Page 1--26

Cincinnati Machine 91203597B001

WARNING

Improper handling of lith ium batteries may cause the batteries to explode, spraying caustic metal, and causing severe chemical burns. Failure to follow this instruction may result in serious personal injury.

Check that the cycle is complete (Cycle Start indicator is not illuminated) andthemachineis inaFeedholdconditionbeforeattemptingtounload/load a workpiece.

Before starting the machine operation (machining), check hydraulic pressures,lubricatingoil pressures, compressedairpressure--if present,and chuck pressure to make sure all gauges indicate proper values.

Battery Replacement

The battery installed in the control unit willprovide backupfor the memory content for approximately 12 months. If an alarm message is displayed on the screen replace the battery as soon as possible. For the correct battery replacement procedure refer to thecontrol manufacturers operating manual.

FANUC alarm message “BAT”.

Lithium Batteries

Lithium batteries contain the hazardous chemical lithium --an extremely active chemical requiring special handling and disposal. The following guidelines should be observed when handling lithium batteries:

 Lithium batteries are not rechargeable.  Do not allow lithium batteries to be heated above 212 degrees F (100

degrees C).

 Do not incinerate lithium batteries.  Do not expose lithium batteries to water. Water may cause a violent

reaction.

 Do not try to disassemble lithium batteries. Direct contact with the

metal causes severe chemical burns.

Because of the hazardous nature of lithium, disposal must be made according to applicable federal, state, and local regulations.

Cincinnati Machine 91203597B001 Page 1--27

Chapter 2 System Information

Fig. 21 Hawk Turning Center

WARNING

MISUSE OF THE MACHINE The machine must not be

adapted to carry out any form of MILLING or GRINDING operations, as its design and construction does not allow for these to be performed safely.

Failureto heed this warning could result in serious personal injury if not death.

Introduction

The CINCINNATI HAWK range of Turning Centers is a general purpose cold metal turning machine, which use non--rotating tools with an indexing turret.

The machine has two sliding axes and tool turret indexing capability all under numerical control.

The turning center has been designed to automatically index tools in order to carry out turning, drilling, threading, boring and reaming operations.

Allfunctionsofthemachinemaybecontrolledbythe NC program, with the minimum of operator attention being required.

The perimeter guarding provided, ensures the safety of personnel against movingparts,coolant,swarfand broken tooling, when the aboveoperations are being undertaken. See WARNING. See also GUARD STRENGTH.

Cincinnati Machine 91203597B001 Page 2--1

WARNING 1

GUARD STRENGTH For safe use of this

machine the guards must be in place and properly maintained. Care must be taken to ensure that cutters are applied within their designed safe speed and that any separate component parts of cutters are securely clamped prior to application.

Failure to follow this instruction may result in serious personal injury.

Guard Strength

The guards of this machine are designed to prevent access to hazardous movingpartsandtocontaintheejectionoftool or work--piece fragments up to a calculated maximum energy level.

For Hawk 150 machines the maximum energy level is 2480 Joules. Thisisequivalent toamassof1.25 kgejectedfromthework areaandhaving an impact speed of 63 m/s.

For Hawk 200/250 machines the maximum energy level is 8000 Joules. This is equivalent to a mass of 2.5 kg ejected from the work area and having an impact speed of 80 m/s.

See WARNING 1.

Page 2--2

Cincinnati Machine 91203597B001

Noise

Noise level for this machine is within a maximum of 80 dB(A). The operating conditions used to determine this figure were as follows:

1. Machine correctlyinstalled,clearofallnearbyreflectingsurfaces with all guards fitted and closed.

2. Noise Measurement positions 1.6m high at operator’s work--station and at six equi--spaced positions along a peripheral path 1.0 from the outer surface of the machine.

3. Noise levels measured using an integrating sound level meter.

4. Machine warmed prior to testing by running for at least 30 minutes at a spindle speed of 66% of max RPM.

5. A--weighted time--averaged emission sound pressure levels measured at each position under the following conditions:

5.1 Machine stopped (hydraulics off) to get background pressure

level. Levels recorded in dB(A) using ’slow’ setting.

5.2 Spindle running at maximum speed with chuck jaws gripping a

dummy workpiece. Emission pressure levels, L

peq

recorded in

dB(A) using ’slow’ setting.

5.3 Machine performing turning operation as detailed in clause 6.2

below, with time--averaged emission pressure levels being recorded, L

peq

6. Operating conditions:

6.1 Mode 1: Running Light Test

Spindle Speed: 5500rpm (Hawk 150) Workpiece: 34mm diameter (dummy) Workpiece holding: 3 j aw chuck

6.2 Mode 2: Prescribed Turning Test

Workpiece: EN 302 Workpiece dimensions: 155mm long, 70mm diameter Workpiece holding: 3 j aw chuck Tooling type: Indexable insert, sintered carbide,

rhomboidal

Tooling geometry: Nose radius: 0.8 mm; Back rake: +9

Cutting edge angle: 95 Spindle speed: 1000 rpm Feedrate: 250 mm/min Depth of cut: 2.0 mm

Metal removal rate: 110 cm

/min Length of cut: 113 mm Duration: 27s

Cincinnati Machine 91203597B001 Page 2--3

WARNING

NOISE LEVEL Running the machine at

high speeds with chuck jaws wide open, could generate noise of a level deemed to be injurious to the hearing of operators or bystanders. Under such circumstances the use of hearing protection is required.

7. All noise emission values corrected for background level.

8. Noise declaration DECLARED SINGLE--NUMBER NOISE EMISSION VALUES in

accordance with ISO 4871, L Maximum A--weighted emission sousnd pressure level L

pAd

, (ref.

20←Pa)attheoperator’spositionoranyperipheralposition,indecibels: Mode 1: Running light at max. spindle speed: 80

Mode 2: Under prescribed operating conditions: 77

9. The operating conditions described herein are considered to be adequately representative of the product, and reflect prevailing usage. Noise levels, under different operating conditions, may, however, exceed the limits quoted, and could under extreme conditions necessitate the use of ear protection equipment. See WARNING.

Failureto heed this warning could result in serious personal injury.

CAUTION

Avoid locating the machine near welding , electrical, or magnetic generating equipment. Possible generating electrical noise may result in machine control interference.

Failure to follow this instruction may result in damage to equipment.

Fumes And Coolant Misting

Extraction equipment can be fitted to the machine. When machining materials which might produce fumes or result in coolant misting, note should be taken of local health and safety regulations.

Fire Hazard

The machine has not been designed to cater for materials which, as a result of the machining application, could combust. It is the owner’s/user’s responsibility in these circumstances to conform with local safety regulations for handling and machining such materials.

Should further advice be required on any of the above items the request shouldbeforwardedtoone of the offices detailed atthe frontof thismanual.

Machine Location -- See Caution EMC Directive Requirements

This machine satisfies the EMC Directive by conforming to generic emissions and immunity standards for the INDUSTRIAL ENVIRONMENT ONLY.

Install the machine in a clean, well lighted area. Ambient temperatures should remain relatively constant to maintain accurate alignment between components, and there should be enough air s pace around the machine to dissipate heat built up during operation. Avoid particularly a location near shipping doors, etc. where air temperatures in winter can fluctuate widely.

Page 2--4

Ensure there will be enough room around the machine to access its componentsformaintenanceandoperation. Suitable lifting devices willbe required for assembly, servicing , and loading/unloading of workpieces.

Cincinnati Machine 91203597B001

WARNING

In order to clearly show details of this machine, some covers, shields, doors or guards have either been removed or shown in an ’open’ position. All such protective devices shall be installed in position before operating this machine.

Failure to follow this instruction may result in damage to machine components and/or personal injury

NC Control

The machine operating station is mounted and positioned at the front of the machine guarding, Protect the control from dust and extremes of temperature and humidity.

Machine Information

Themachineand controlareintegratedto compriseanefficientmanufacturingsystem.Thus,m achining cycles can be completely automatic,including toolselection,toolpositioning,selectionofspindlespeedsandcuttingfeeds, coolant control with other related auxiliary functions and/or combinations of control. The machine and controls are completely compatible, each taking advantage of the capabilities of the other.

The basic machine consists of the following units: Fixed base

Fixed headstock/spindle Sliding saddle (Z axis) Sliding turret (X axis) Multi--station indexing turret Hydraulic chuck and cylinder Hydraulic tailstock Computer Numerical Control Station Electrical Cabinet Chip/Coolant Tray Perimeter Guards

Bed/Base Unit Thebed/base unit is the main structure of the TurningCenter.In addition to...................

Headstock Spindle Unit The headstock spindle unit contains the necessary components t o drive the............

Saddle The sliding saddle provides the Z axis travel...........................

Turret Theturretis located on the saddle. The turret providesthe X axis travel and..........................

Chip / coolant tray The chip tray is positioned under the base at the front of the machine.................

Coolant tank Lshaped,lyingacrossthefrontandRighthandendofthemachine.Theunit.....................

providing rigidity and support for the sliding members, machine alignment is maintained through the strength of this structure. The unit houses the following;

Spindle drive motor Hydraulic tank and pump unit -- bolted to the Left Hand end of the Bed/Base unit. Electrical Cabinet

spindle through range of speeds in one (1) RPM increments. The spindle is powered by a motor whose speed selection is accomplished via CNC.

also carries the multi--station indexing turret.

houses the coolant pump.

Cincinnati Machine 91203597B001 Page 2--5

Axis Orientation

Fig. 22 Axis Orientation -- Hawk Turning Centre

-Z

-X

Theaxisorientationphotographenablestheoperatortoaffixinhismindthe conventional slide directions of movement for the turning center. The photograph is for axis orientation only and does not represent the mechanical zero reference points for these axes.

Page 2--6

Cincinnati Machine 91203597B001

Hawk Specification

Chuck

Turn length max mm 440 540 690......................................

Jaw chuck diameter max mm 210 254 304...............................

max swing over bed mm 400 530 530...................................

max turn diameter (STD tooling) mm 240 300 350.........................

Bar chuck capacity mm 51 65 77....................................

Axis Travel Ranges

Turret slide (X axis) mm 215 245 270...................................

Saddle (Z axis) mm 440 540 690.......................................

Spindle

AC Drive Motor continuous rated kW 5.5 11 15........................

duty rated kW 7.5 15 18.5............................................

Spindle speed max rpm. 5500 4500 3300....................................

Nose . A2--5 A2--6 A2--8...............................................

Bearing type . A/C A/C A/C.........................................

Bearing size -- Bore mm. 90 110 130...................................

Units 150 200 250

Linear Axis Feedrates and Thrust

Feedrate Z m/min 24..........................................

Rapid rate Z m/min 24.........................................

Axis thrust Z kN 5.6........................................

Accuracies -- Uni--directional

Positioning Z mm 0.004........................................

Axis repeatability Z mm 0.001..................................

Tooling

Turret positions 12 12 12......................................

Index time per station s 0.2 0.3 0.3.................................

Tooling type (Standard) V.D.I.30 V.D.I.40 V.D.I.40................................

Tailstock

Quill diameter mm 65 95 95.......................................

Quill stoke mm 101 127 127..........................................

Quill thrust kN 4.5 7.8 7.8..........................................

Quill taper 4 M.T 5M.T 5M.T..........................................

X m/min 16..................................................

XkN4.0..................................................

Xmm0.002..................................................

Xmm0.0005..................................................

Cincinnati Machine 91203597B001 Page 2--7

Hawk Specification Units 150 200 250

CNC System

Model and type FANUC 21i......................................

Manufacturer G.E. FANUC........................................

Number of contouring axes ONE (X Axis).............................

Lubrication System

Axes ballscrew nuts grease P64..............................

X,Y,Z axis way bearings grease P64..........................

Spindle bearing lubrication pre--greased sealed.............................

Coolant System

Coolant delivery system -- Low Pressure at 0.9 Bar l/min 20..........

Coolant delivery system -- High Pressure at 5.2 Bar l/min 20..........

Head m 5...............................................

Tank capacity without conveyor l 135 177 190.........................

with conveyor l 155 205 218........................................

Hydraulic System

Oil specification P38......................................

Tank capacity l 45.......................................

Air Requirement

Air supply pressure bar 61...................................

Continuous volume ANR dm3/s 5..............................

Electrical Power Requirement

Spindle drive motor kVA 9 25 37...................................

Axis motors X, Z kVA 3 3 3.....................................

Turret Indexing motor kVA 1.5 1.5 1.5.................................

Hydraulic pump motor kVA 3 3 3.................................

Coolant pump motor -- Low Pressure VA 650 650 650.....................

Coolant pump motor -- Low Pressure kVA 3.5 3.5 3.5.....................

Control gear VA 750 750 750.........................................

Machine Weight/Floor Space

Machine net weight approx. kg 4000 4500 5000.............................

Overall machine height (max) m 1.62 1.8 1.8...........................

Machine width m 1.5 1.9 1.9.......................................

Machine length without swarf conveyor m 2.4 3.0 3.46 Machine length with swarf conveyor m 3.2 3.9 4.3

Allillustrationsand specificationscontainedinthis literatureare basedonthe latestproductinformation availableatthe timeof publication. The right is reserved to make changesatanytime without notice in prices, materials, equipment, specifications,andmodelsand to discontinue models. In addition, all dimensions are nominal and can vary with machine model change.

Page 2--8

Cincinnati Machine 91203597B001

Machine And Range Drawings

This section provides machine and range drawings for the Hawk range of turning centers.

Z AXIS TRAVEL

125

100

3.45

3.0

2.4

4.3

3.9

3.2

1075

804

250

690

DISCHARGE

HEIGHT

SWARF

CONVEYOR

FLOOR LEVEL

200

540

QUILL TRAVEL

150

HAWK

440

CNC

CONTROL

STATION

Fig. 23 Front View

Cincinnati Machine 91203597B001 Page 2--9

O/L LENGTH WITHOUT CONVEYOR

O/L LENGTH WITH CONVEYOR

The Information shown is general in nature. For

absolute working dimensions refer to Dedicated

Engineering Drawings supplied with the machine

HEIGHT OF MACHINE

’X’ AXIS TRAVEL

The Information shown is general in nature. For absolute working dimensions refer to Dedicated Engineering Drawings supplied with the machine

Fig. 24 Left Side View

Page 2--10

MACHINE WIDTH

HAWK

A B C

150 215

1.6

1.5

200 245

1.8

1.9

FLOOR

250 270

1.8

1.9

Cincinnati Machine 91203597B001

A PART OFF TOLHOLDER ADJACENT TO A SHORT

TOOLHOLDER (ON EITHER SIDE) PRESENTS VIRTUAL-

The Information shown is general in nature. For absolute working dimensions refer to Dedicated Engineering Drawings supplied with the machine

203 MAX.TURNING TO SPEC.

LYNO INTERFERENCE EVEN WHEN FACING DOWN TO

CENTRE. PARTING TOOL IS CLOSER TO DISC THAN

THE TURNING TOOL..

MAX BORING BAR - Ø32

TURNING TOOL- 20 X 20

DISC VDI.30.

DISC P.C.D. - 270

DISC O/DIA -340

CHUCK STD- Ø170

CHUCK SPC’L - Ø210

A LONG TOOLHOLDER ADJACENT TO A SHORT TOOLHOLDER

(ON EITHER SIDE) PRESENTS VIRTUALL YNO INTERFERENCE

187 R.TOOLING ENVELOPE.

MAX.TURNED FACE

(OUTSIDE SPEC.)

MAX.TURNING

BY SPEC

203

EVEN WHEN FACING DOWN TO THE CENTRE- LINE.

203

270

126. LARGEST DIA. BLANK IN CHUCK WHICH CAN BE

PARTED;

WITH A TURNING TOOLHOLDER IN THE NEXT AD-

JACENT POSITION

210 CHUCK

50.8 (2”) MAX. BAR. DRAW TUBE BORE 52MM

203 THEORETICAL MAX TO SPEC’N

202 R.PARTING- TOOL ENVELOPEAPPROX.

215 ’X’AXIS TOTAL WORKING STROKE

170 CHUCK

ING BY SPEC.

27.4

270 VDI.30,PCD

323 DISTANCE TO SPINDLE

30 VDI

340 DISC.

109.5,LARGEST COMPONENT SWING BETWEEN BORING- BARS ON AD-

JACENT TURRET POS’NS.

BORING BARS OF SIMILAR LENGTH ARE NOT RECOMMENDED TO BE PUT

INTO ADJACENT DISC POSITIONS; BUT SHOULD FOLLOW THE GENERAL

RULE OF BEING LOADED INTO THE DIAGONALLYOPPOSED STATIONS.

218 R.TOOLING ENVELOPE.

210 MAX TURNING.

LONG TOOLHOLDER.

(OUTSIDE SPEC.)

203 MAX TURN-

Fig. 25 Turning Capacity Chart -- Hawk 150 (VDI Tooling)

Cincinnati Machine 91203597B001 Page 2--11

The Information shown is general in nature. For absolute working dimensions refer to Dedicated Engineering Drawings supplied with the machine

Ø254 MAX. TURNING

BY SPEC.

A PART OFF TOOLHOLDER ADJACENT

TOA SHORTTOOLHOLDER (ONEITHER

SIDE)PRESENTSVIRTUALLYNOINTER-

FERENCE EVEN WHEN FACING DOWN

TOCENTRE. PARTING TOOL ISCLOSER

TO DISK THAN THE TURNING TOOL

Ø306.5MAX. TURNED FACE

(OUTSIDE SPEC)

Ø254 THEORETICAL MAX.

TO SPECIFICATION

Ø66 DRAWTUBE

BORE

Ø254 MAX. TURNING

BY SPEC.

Ø166.5 LARGEST DIA BLANK IN CHUCK

WHICH CAN BE PARTED, WITH A TURNING

TOOL HOLDERIN THE NEXT ADJACENT POCKET

TURNING CAPACITY CHART

R262.5 PARTINGTOOL

ENVELOPE APPROX.

245 ’X’ AXIS TOTAL WORKINGSTROKE

R234.5 TOOLING

R267.7 TOOLING ENVELOPE

254 MAXTURNING BY SPEC

ENVELOPE

Ø40 VDI

Ø410DISK

Ø340 P .C.D.

R388 DISTANCE TO

SPINDLE CENTRE LINE

Ø130.5 LARGEST COMPONENT

Ø254 CHUCK

Ø200 CHUCK

SWING BETWEEN BORING BARS

ON ADJACENT TURRET POSITIONS

BORING BARS OF SIMILAR LENGTH

ARE NOT RECOMMENDED TO BE PUT

INTO ADJACENT DISK POSITIONS,

BUT SHOULD FOLLOW THE GENERAL

RULE OF BEING LOADED INTO THE

DIAGONALLYOPPOSED STATIONS.

A LONG TOOLHOLDER ADJACENT TO

A SHORT TOOLHOLDER (ON EITHER

SIDE) PRESENTS VIRTUALLY NO IN-

TERFERENCE EVEN WHEN FACING

DOWN TO THE CENTRE LINE

240 MAX TURNING (LONG TOOLHOLDER)

OUTSIDE SPEC

Fig. 26 Turning Capacity Chart -- Hawk 200 Machines (VDI Tooling)

Page 2--12

Cincinnati Machine 91203597B001

Ø305 MAX. TURNIING

BY SPEC.

Ø356.61 MAX TURNED FACE

(OUTSIDE SPEC)

Ø196.5 LARGEST DIA BLANK IN CHUCK

WHICH CAN BE PARTEDWITH A TURNING

TOOLHOLDER IN THE NEXT ADJACENT

POCKET.

R264.7 TOOLING

ENVELOPE

A LONG TOOLHOLDER ADJACENT TO A

SHORT TOOLHOLDER (ON EITHER SIDE)

PRESENTS VITUALLY NO INTERFERENCE

EVEN WHEN PARTING DOWN TO THE

CENTRE LINE.

Ø78 DRAWTUBE BORE

R292.5 PART TOOL ENVELOPE

270 ’X’ AXIS TOTAL WORKING

STROKE.

Ø250 CHUCK.

Ø315 CHUCK.

TURNING CAPACITY CHART

R297.7 TOOLING ENVELOPE

Ø305 MAX. TURNIING BY SPEC.

290.6 MAX TURNING (LONG

TOOLHLDER) OUTSIDESPEC

The Information shown is general in nature. For absolute working dimensions refer to Dedicated Engineering Drawings supplied with the machine

40 V.D.I

Fig. 27 Turning Capacity Chart -- Hawk 250 Machines (VDI Tooling)

Ø162.3 LARGEST COMPONENT SWIN

G BETWEEN BORING BARS ON AD-

JACENT TURRET POSITIONS

BORING BARS OF SIMILAR LENGTH

ARE NOT RECOMMENDED TO BE PUT

INTO ADJACENT DISK POSITIONS

BUT SHOULDFOLLOW THEGENERAL

RULEOF BEING LOADED INTO THEDI-

AGONALLYOPPOSED STATIONS.

Ø305 MAX.TURNIING BY

SPEC.

Ø400 P.C.D

Ø470 DISK

A PART OFF TOOLHOLDER ADJACENT

TOA SHORTTOOLHOLDER(ONEITHER

SIDE) PREENTS VIRTUALLY NO INTER-

FERENCE EVEN WHEN FACING DOWN

TOCENTRE. PARTINGTOOL ISCLOSER

TO DISK THAN THE TURNINGTOOL.

Cincinnati Machine 91203597B001 Page 2--13

(

)

320 SLIDE WIDTH

4356438

DUPLOMATIC INDEXER

BSA 150

The Information shown is general in nature. For absolute working dimensions refer to Dedicated EngineeringDrawingssupplied with themachine.

TAILSTOCK

FULLY BACK

173.7

105

101.6 QUILL

STROKE

475.8 TAILSTOCK

ADJUSTMENT

215 MAX STROKE

189

190

52 68

25 25

TYP’

PCLNL

2020K12.

,RAD.135

27.410 8 O/TRAVEL

27.4 8

173.7 O/HANG

101.6 QUILL

438MAX WORKING STROKE

402 STROKE TO HARD JAWS ONS.M.W. 170 CHUCK

418STROKE TOHARDJAWS ONKITAGAW A170CHUCK

123

454 ABSOLUTE STROKE

KITAGAWA170--52

STROKE

223

139

SMW--169.

OVERTRAVEL

FRONT FACE BULKHEAD

FRONT FACE HEADSTOCK

Fig. 28 Data Sheets -- Hawk 150

Page 2--14

DI Toolin

Cincinnati Machine 91203597B001

The Information shown is general in nature. For absolute working dimensions refer to Dedicated EngineeringDrawingssupplied with themachine.

65.1

190

100

177.91

127.00

QUILL STROKE

245 MAXSTROKE

10 O/TRAVEL

TAILSTOCK

FULLY

BACK

665.50 TAILSTOCKTRAVEL

1250 TOCLEAR ’X’ TRAVEL

267.7 LONG

TOOLHOLDER

190

Fig. 29 Stroke -- Hawk 200 Machines (VDI Tooling)

560 ABSOLUTE STROKE

540 MAX. WORKINGSTROKE

540 TO KITAGAWA BB08--66 CHUCK FACE

539 TO SMW BHM210--A6 CHUCK FACE

255.6

SMW HARD JAWS

12082121

358.6

104

SMALL SMW

10 O/TRAVEL

388 FROM OF DISK TO OF

SPINDLE

BULKHEAD FRONT FACE

HEADSTOCK FRONT FACE

103

SMALL KITAGAWA

4 SERRATIONS

Cincinnati Machine 91203597B001 Page 2--15

The Information shown is general in nature. For absolute working dimensions refer to Dedicated EngineeringDrawingssupplied with themachine.

177.91

127.00

QUILL STROKE

TAILSTOCK

FULLY

BACK

190

64.6

100

97.7 32

Ø40

Ø83

297.7 LONG

TOOLHOLDER

443 FROM OF DISK TO

OF SPINDLE

70 ABSOLUTE STROKE

690 MAX. WORKING STROKE

119

O/TRAVEL

BULKHEAD FRONT FACE

HEADSTOCK FRONT FACE

270 MAX. STROKE

10O/TRAVEL

690 TO SMW BBM250--A8 CHUCK FACE

690 TOKATAGAWA B210--A8 CHUCK FACE

179

SMALL

SMW

234.09

SMW HARD

JAWS

12082621

4 SERRATIONS

897 TAILSTOCKTRAVEL

1530.62

(347.09)

173

113 SMALL

KITAGAWA

Fig. 30 Stroke -- Hawk 250 Machines (VDI Tooling)

Page 2--16

Cincinnati Machine 91203597B001

The Information shown is general in nature. For absolute working dimensions refer to Dedicated EngineeringDrawingssupplied with themachine.

B1;30/20:212--100--150. RECTANGULAR TRANSVERSE TOOLHOLDER,R.H.SHORT.

B3;30/20:212--105--150. RECTANGULAR TRANSVERSE INVERTEDTOOLHOLDER, RIGHT--HAND;SHORT.

B7;30/20:222--105--150. RECTANGULAR TRANSVERSE INVERSE TOOLHOLDER, RIGHT--HAND:LONG.

TYP’.35

27.4,TYP’.

SQ.

30.

10H6. 12H6.

OPTIONAL STANDARD TOOLING PACKAGE.

001270504000001.

E1;30/25:222--052--150 TOOLHOLDER WITH:-INTERNALCOOLANTSUPPLY.

E1;30/32:222--055--150 TOOLHOLDER WITH:-INTERNALCOOLANTSUPPLY.

E2;30/30:212--015--156 BORINGBAR HOLDER.

16H6.

ONE SET OF FIVE LINERBUSHES.

20H6.

82.4

MAX.-- IF USINGFULL STROKE.190

.45

.68

52.

H6.32

25H6.

30H6.

68.

Fig. 31 Optional Standard Tooling Package -- Hawk 150 (VDI Tooling)

Cincinnati Machine 91203597B001 Page 2--17

The Information shown is general in nature. For absolute working dimensions refer to Dedicated EngineeringDrawingssupplied with themachine.

DRILL HOLDER -- VDI 40 Dia 32

(WITHINTERNAL COOLAND SUPPLY)

FORM E1

27.4032

DIN 69880

PARTING O FF BLADE HOLDER -- VSI 40 --

RIGHT HAND

32.SH32

32.4032

TURNING TOOL -- VDI 40 -- RIGHT HAND LONG

FORM B5

11.4025/20

OPTIONAL STANDARD TOOLING

DIN 69880 PART 3

PACKAGE 1946177

TURNING TOOL -- VDI 40 -- RIGHT HAND SHORT OVERHEAD

FORM B3

6.4025/20

DIN 69880 PART 3

TURNING TOOL -- VDI 40 -- RIGHT HAND SHORT

FORM B1

5.4025/20

DIN 69880

BORINGBAR HOLDER -- VDI 40 Dia 40

FORM E1

27.4032

Ø32

Ø74 Ø52

DIN 69880

BORINGBAR SLEEVE

Ø25

28.4025

PLASTIC PLUG -- VDI 40

FORM Z2

29.40K

DIN 69880

BORINGBAR SLEEVE

Ø20

28.4020

ONE SET OF FOURLINER BUSHES

COLLET CHUCK -- VDI 40 ER32 TYPE

FORM E4

30.4032

DIN 69880

BORINGBAR SLEEVE

Ø16

28.4016

Ø20 H6 Ø25 H6

Ø16 H6

Ø40

BORINGBAR SLEEVE

Ø12

Ø83 Ø40

Fig. 32 Optional Standard Tooling Package -- Hawk 200/250 Machines (VDI Tooling)

Page 2--18

28.4012 Ø12 H6

Cincinnati Machine 91203597B001

gOp

190.

130. 185.

Ø130 Ø185

60.

Ø60

138.9

108.9

156.9

SMW.KSZ,MB60.

COLLET CHUCK.

49 MIN

SMW.HARD JAW

1282030.CM#:--

1270486000001

10.5

SERRATIONS.

OFJAW

160

150

SMW.210,BH D.

72 MAX

72,MAX.

49,MIN.

C’BORE

FORM12.

52.

Ø52

210

Ø210

M12

165

COLLET CHUCK.

KITAGAWACRL60.

HARD JAWS

HB,08A1.CM#:- -

1270575000001

M10

156

111

KITAGAWAB208,A5.

138.

Ø138 Ø150

60.

Ø60

148

M10

210

Ø20

,MIN.45.5

68.7,MAX.

STROKE3.7

PERJ AW.

45.5 MIN

68.7 MAX

C’BORE

FORM10.

52.

Ø52

108

63.5,MAX.

46.5,MIN.

46.5 MIN

SMW.HARD JAW

12081621.CM#:--

1270485000001

139

SMW--170--52

63.5 MAX

C’BORE

FORM10.

52.

170.

Ø170

M10

The Information shown is general in nature. For absolute working dimensions refer to Dedicated Engineering Drawings supplied with the machine.

Fig. 33 Work Holdin

tions -- Hawk 150

HARD JAWS

HB,06B1.CM#:- -

1270572000001

123

M12

123

67.5

KITAGAWA170--52

8.5

13.75

48,MIN.

60,MAX.

C’BORE

FORM10.

M10

52.

Ø52

170.

Ø170

BULKHEAD FRONT FACE

HEADSTOCK FRONT FACE.

Cincinnati Machine 91203597B001 Page 2--19

The Information shown is general in nature. For absolute working dimensions refer to Dedicated EngineeringDrawingssupplied with themachine.

KITAGAWA CHUCKING SYSTEM

Ø165

Ø150

Ø65

140

100

120

Ø75 254

B210--A6 CRS66--A6

BULKHEAD FRONT FACE HEADSTOCK FRONT FACE

BULKHEAD FRONT FACE

HEADSTOCK FRONT FACE

BB08--66

Fig. 34 Work Holding Options -- Hawk 200

Page 2--20

Ø200Ø66

BULKHEAD FRONT FACE HEADSTOCK FRONT FACE

103

Cincinnati Machine 91203597B001

The Information shown is general in nature. For absolute working dimensions refer to Dedicated EngineeringDrawingssupplied with themachine.

BHM--250--A6

SMW CHUCKING SYSTEM

Ø250

Ø75

105

124

Ø210

BULKHEAD FRONT FACE HEADSTOCK FRONT FACE

321

Ø66

BBM--210--A6

BULKHEAD FRONT FACE HEADSTOCK FRONT FACE

104

Fig. 35 Work Holding Options -- Hawk 200

Cincinnati Machine 91203597B001 Page 2--21

The Information shown is general in nature. For absolute working dimensions refer to Dedicated EngineeringDrawingssupplied with themachine.

❤

220

200

❤

KITAGAWA CHUCKING SYSTEM

B212--A8

CDC80A2 (1273393)

11mm

STROKE

159

304

170

❤❤❤❤

BULKHEAD FRONT FACE

HEADSTOCK FRONT FACE

❤❤❤❤

110

122

B210--A8

Fig. 36 Work Holding Options -- Hawk 250

100

113

BULKHEAD FRONT FACE

HEADSTOCK FRONT FACE

254

BULKHEAD FRONT FACE

HEADSTOCK FRONT FACE

Page 2--22

Cincinnati Machine 91203597B001

gOp

The Information shown is general in nature. For absolute working dimensions refer to Dedicated EngineeringDrawingssupplied with themachine.

SMW CHUCKING SYSTEM

315 95

BHM 315-- AB

BULKHEAD -- FRONT FACE HEADSTOCK -- FRONT FACE

111

136

250 77

BBM 250--A8

BULKHEAD -- FRONT FACE

HEADSTOCK -- FRONT FACE

105

119

Fig. 37 Work Holdin

Cincinnati Machine 91203597B001 Page 2--23

tions -- Hawk 250(Continued

350 APPROX

CLEARANCE REQUIRED

5500 MIN

BEHIND MACHINE

3000 BAR CAPACITY

4900 MIN

3210 APPROX1520 APPROX

5180

CLEARANCE REQUIRED BEHIND MACHINE

2700

450 APPROX

720

1770

1670

BAR FEEDSHOWN ROTATED THROUGH 90° AND 135°

4800 OVERALL LENGTH

3000 BAR CAPACITY

1064 BASE

1150

PLAN VIEW OF BASE

1975 BASE

1150REF

MULTIFEED3 -- 76

SHORT MAGAZINE BAR

FEED OPTION

The Information shown is general in nature. For absolute working dimensions refer to Dedicated Engineering Drawings supplied with the machine

91203090A

Fig. 38 Bar Feed O

Page 2--24

tions -- Hawk 150 machines

Cincinnati Machine 91203597B001

Motor Rating

The MTD (Machine Tool Duty) rating of the motor is based upon the amount of power delivered in a given amount of time. The following chart shows spindle motor MTD ratings.

7.5 kW

5.5 kW

POWER

Machine Hawk Model 150 7.5 5.5 Hawk Model 200 15 11 Hawk Model 250 18.5 15

MTDR

Continuous

30 750 3,500

MTD Rating Continuous Use

5.0 kW

4.5 kW

5,500

Fig. 39 Hawk 150 -- Spindle Power Characteristics

15 kW

11 kW

POWER

30 750 4,500

SPEED RPM

MTDR

Continuous

SPEED RPM

Fig. 40 Hawk 200 -- Spindle Power Characteristics

Cincinnati Machine 91203597B001 Page 2--25

15 kW

11 kW

POWER

MTDR

Continuous

30 575 3,300

Fig. 41 Hawk 250 -- Spindle Power Characteristics

SPEED RPM

Page 2--26

Cincinnati Machine 91203597B001

X+

SPINDLE FACE

MACHINE ALIGNMENT AND PROGRAM POINTS

On Turning Centers, the Z axis travels parallel to the spindle centerlineand the X axis travels perpendicular to the spindle centerline.

Several real and imaginary points are used to describe the relationship between the machine elements, the tool point, and the workpiece. There are manyreferences to these points throughout themanual.Thissectiondefines themachinesetupandalignmentpoints. RefertoMachineRangedrawings.

Z+

CHUCK

SPINDLE CENTERLINE

Fig. 42 Machine Alignment And Program Points

MACHINE ZERO

OD COMMON TOOLPOINT ATGRIDALIGN POSITION

Machine Zero

Machine zero in the X axis is located on the spindle centerline. Machine zero is established only once each time the machine is startedand

aligned. The control calculates all automatic range checking and interference parameters from machine zero.

NOTE: When coordinate reset is active and the machine is aligned, pro-

gram zero is also located at this point.

Cincinnati Machine 91203597B001 Page 2--27

Chapter 3 Functional Description of Controls

Introduction -- GE FANUC 21i--TA CNC System

The GE Fanuc 21i--TA CNC system control consist of a Control mounted behindflatscreenwithsoftkeys,MDIkeypad,OperatorsControlPanel,and an MTB panel (Machine Tool Builders panel).

ForfulldescriptiononusingthePCMIAslot and softkeysonthecontrol/flat screen unit and also the MDI keypad unit reference should be made to GE FanucOperatorsmanual (21i--TAB--63084EN)suppliedwiththismachine.

The Hawk Turning centre is arranged with GE Fanuc 21i--TA Computer Numerical Control System comprising an operator control station with a

9.5” high resolution monochrome flatscreen display. See Fig. 43.

Control/Flat Screen/Softkeys MDI Keypad

PC MIA Slot (SRAM) Card

-- +

RS 232 Serial Data Port

Fig. 43 Control Station Layout for:

-- Hawk Turning centres with fanuc 21i TA

F 3

1 0

-- Z + Z

-- X

+--

Operators Control MTB Panel

Cincinnati Machine 91203597B001 Page 3--1

123 45678910

RS 232

Fig. 44 Operators Control Panel

X Z

100%

+-U

AUX

X1 X10 X100

-- +

+ X

-- Z

-- X

OPERATOR PANEL -- PUSHBUTTON DESCRIPTIONS

REF DESCRIPTION REF DESCRIPTION A1

A2 A3 A4 A5 A6 A7 A8 A9 A10 B1 B2 B3 B4 B5 B6 B8 B9 B10 C1 C2 C3 C4

Memory Operation C5 Turret Jog -- (decrement) EDIT mode C6 AUX 1 -- spare membrane key MDI Operation C8 -- Z axis JOG/MPG axis selection Align Machine C9 Rapid traverse Jog mode C10 +Z axis JOG/MPG axis selection Parts catcher down D1 Program restart Parts catcher up D2 Tool Setting Arm Down (active) Chuck -- ID Grip D3 Tool Setting Arm Up (stowed) Chuck -- OD Grip D4 Spindle speed decrement Offset measure D5 Spindle 100% Single block D6 Spindle speed increment Block delete D8 Optional stop D9 --X axis JOG/MPG axis selection MPG mode x 1 D10 MPG mode x 10 F1 Cycle start MPG mode x 100 F2 Cycle stop

F3 Program stop

+X axis JOG/MPG axis selection F4 Spindle clockwise (CW)

F5 Spindle stop

Dry run F6 Spindle counterclockwise (CCW) Program test F8 Coolant On Axes inhibit F9 Coolant Off Turret Jog + (increment) F10 Coolant Auto

Page 3--2

Cincinnati Machine 91203597B001

AUTOMATIC OPERATION -- PROGRAMME SOURCE

MEMORY OPERATION -- (Push button with LED) (A1)

This mode is selected to run a part programme registered in the active programme memory. (See GE Fanuc Operators Manual -- III Operation chapters 1.2 and 4.1).

EDIT MODE -- (Push button with LED) (A2)

This mode is selected to edit part programmes registered in the active programme memory. (See GE Fanuc Operators Manual -- III Operation chapters 9).

MDI OPERATION -- (Push button with LED) (A3)

This mode selection enables a programme of up to 10 blocks to be created and processed from the MDI buffer memory. (See GE Fanuc Operators Manual -- III Operation chapters 1.2 and 4.2).

EXECUTION PUSHBUTTONS

CYCLE START (Push button with LED) (F1)

This push button causes the active NC programme to start, providing that the following conditions are met:--

1) All axes have been aligned.

2) The turret is aligned, i.e. ALIGN MACHINE key is illuminated

3) No NC or Machine faults are active

4) AUTO or MDI mode has been selected

5) Operator door/s is/are closed

CYCLE STOP (Push button with LED) (F2)

Cycle stop is used to stop all feed motors and to suspend the NC cycle. TheLEDin thisbutton isilluminatedwhenevertheCYCLESTOPisactive.

It is cancelled whenrestartingthe NC cycleusing the CYCLE STARTpush button.

NOTE: Any active programme dwell will also be stopped by using this

push button. If CYCLE STOP is depressed during a Tapping Cycle the NC cycle will continue until the spindle has reversed and the axis retracted.

Cincinnati Machine 91203597B001 Page 3--3

PROGRAMME STOP (Push button with LED) (F3)

Pressingthis push button during NC part programmedexecutioncausesthe activecycleto be held at the end of the current programmeblock. Torestart the active part programme, the CYCLE START push button must be depressed.

Itispermittedtostop the spindle whilst ina programmestop condition. The NC cycle however cannot be resumed until the spindle has been restarted.

PROGRAMME STOP push button is active in both AUTO & MDI modes but only whilst the machine is in cycle.

The LED in this push button is illuminated when programme stop is active and remains illuminated until the cycle is restarted or the control system is reset.

SPINDLE CONTROL BUTTONS

SPINDLE STOP (Push button with LED) (F5)

Thispushbutton causesanimmediatespindlestop and is activeatalltimes. If the machine is in cycle, a cycle stop is also generated. The LED in this button is illuminated if the spindle is stopped during an

Auto Cycle interrupt condition and acts as a reminder that the spindle must be restarted before the cycle can be resumed.

SPINDLE CLOCKWISE (CW) (Push Button with LED) (F4)

This push button can be used to restartthe spindle, once it has beenstopped during an Auto Cycle Interrupt.

In C--Axis Mode OFF (M50 active), this button can also be used to jog the spindle in the clockwise direction providing the control is not in cycle or in a cycle interrupt condition, and only when the operator door is closed. See

CAUTION.

In C--Axis Mode ON (M51 active), this button, in conjunction with the control set in JOG mode, can be used to jog the spindle in the clockwise direction. The operator door is latched shut at all times when M51 is the active M--code. See CAUTION. Also, see HANDWHEEL (MPG) for alternative spindle jog facility.

SPINDLE COUNTER CLOCKWISE (CCW) (Push button with LED) (F6)

This push button can be used to restartthe spindle, once it has beenstopped during an Auto Cycle interrupt.

Page 3--4

In C--Axis Mode OFF (M50 active), this button can also be used to jog the spindle in the CCW direction providing the control is not in cycle or in a cycle interrupt condition, and only when the operator door is closed. See

CAUTION.

In C--Axis Mode ON (M51 active), this button, in conjunction with the control set in JOG mode, can be used to jog the spindle in the CCW direction. The operator door is latched shut at all times when M51 is the

Cincinnati Machine 91203597B001

active M--code. See CAUTION. Also, see HANDWHEEL (MPG) for alternative spindle jog facility.

CAUTION Spindle Jog

TheSpindle/Chuckmust be in an interference free position before pressing the SPINDLE CW/CCW pushbutton.

Failure to follow this instruction may result in damage to the machine, workpiece and tooling.

SPINDLE 100% (Push button with LED) (D5)

100%

This push button is used to return the actual spindle speed to 100% of the last programmed value and to remove any active spindle speed override imposed by means of the spindle speed increment and decrement buttons.

TheLEDin this push buttonisilluminatedallthetime that the 100%spindle speed override is active

SPINDLE SPEED INCREMENT (Push button with LED) (D6)

This push button is used to override the programmed spindle speed. The actual spindle speed is increase by 10% each time this button is depressed, up to a maximum of 120% of the programmed value or the the maximum spindle speed if this occurs sooner.

TheLEDin this pushbuttonisilluminatedoncethe 120%overrideis active. NOTE: Spindle override is ignored whilst M48 is active

SPINDLE SPEED DECREMENT (Push button with LED) (D4)

This push button is used to override the programmed spindle speed. The actual spindle speed is decreased by 10% each time thisbutton is depressed, down to a minimum of 50% of the programmedvalue or the the minimum spindle speed if this occurs sooner.

TheLED in this push button is illuminated once the 50% overrideis active. NOTE: Spindle override is ignored whilst M48 is active

OPERATION BUTTONS

ALIGN MACHINE -- (Push Button with LED) (A4)

This pushbutton is used for referencing the machine axes and turret to the control system. (See chapter 4 of this manual for machine and mechanism alignment procedure).

MPG MODE (HANDWHEEL) & INCREMENT SELECTION PUSHBUTTONS

MPG MODE -- 0.001mm (Push Button with LED) (B4)

This pushbutton selects MPG Mode with 0.001mm distance move per

Cincinnati Machine 91203597B001 Page 3--5

increment of the handwheel.

X10

X100

MPG MODE -- 0.010mm (Push Button with LED) (B5)

This pushbutton selects MPG Mode with 0.010mm distance move per increment of the handwheel.

MPG MODE -- 0.100mm (Push Button with LED) (B6)

This pushbutton selects MPG Mode with 0.100mm distance move per increment of the handwheel.

JOG MODE -- (Push Button with LED) (A5)

This button accesses the ’axis and direction’ push button selections to provide ’continuous move’ axis jogs. (See push button references B9, D9, C8andC10 in this manual,andGEFanucOperatorsManual -- IIIOperation chapter 3.2).

In C--Axis Mode ON (M51 active), manual rotation of the spindle/chuck using the Handwheel (MPG) control is possible proivided JOG mode is selected ON.

OPERATION SELECT -- PUSHBUTTONS

SINGLE BLOCK -- (Push Button with LED) (B1)

Thispushbuttonallowsanactivepart programmetobeprocessedone block at a time. When this feature is active each block must be started using the CYCLE START push button. The single block push button is enabled in AUTO & MDI mode. The LED is illuminated when SINGLE BLOCK is active.

NOTE: It is permitted to use this push button to interrupt an active cycle.

Foraffectofsingleblockon cannedcyclesrefer toGEFanucoperators manual.

BLOCK DELETE -- (Push Button with LED) (B2)

When BLOCK DELETE is active all programme blocks preceded by the BLOCK DELETE character (/) are skipped during an NC cycle This push button is enabled only in AUTO & MDI mode.

The LED is illuminated when BLOCK DELETE is active.

OPTIONAL STOP -- (Push Button with LED) (B3)

This push button enables the OPTIONAL PROGRAMME STOP feature. Whenoptionalstopis active the NC cyclewill stop on readingan M01 code and can only be restarted by pressing the CYCLE START push button, all existing modal programme information is unaffectedby this function. This push button is enabled in AUTO & MDI mode only.

Page 3--6

The LED is illuminated when OPTIONAL STOP is activate.

DRY RUN -- (Push Button with LED) (C1)

When the DRY RUN feature is active, coolant flow is inhibited and the feedrate specified by the NC programme is ignored.

The OVERRIDE SELECTOR switch is used to modify the DRY RUN feedrate from 0. 1M/min. to 10 M/min.

Cincinnati Machine 91203597B001

Rapid motions are conducted as normal and can also be overridden by the OVERRIDE SELECTOR.

This push button is enabled in AUTO & MDI mode. The LED is illuminated when DRY RUN is active. Dry run can only be selected when the machine is not in cycle. To start the cycle in dry run requires a double press of the CYCLE START

push button. On the first press an operator prompt message DRY RUN ACTIVE REPRESS CYCLE START appears on the CRTas a warning that DRY R UN is active.

PROGRAMME TEST -- (Push Button with LED) (C2)

When the programme test feature is active, all T and S codes and all of the M codes with the exception of:M00, M01, M02, M30, M98 and M99 are not processed.

Thispushbutton is enabledinAUTO& MDImode.TheLEDisilluminated when programme test is active.

PROGRAM TEST is used during programme checking and may also be used in conjunction with AXES INHIBIT.

AXES INHIBIT -- (Push Button with LED) (C3)

Axes inhibit suppresses all axis moves. The CRT display however is updated as if the axis were not inhibited.

Thispush button is only enabledinAUTO&MDImodewhilst not in cycle. The LED is illuminated when AXIS INHIBIT is active.

Axes inhibit is used during programme checking and may also be used in conjunction with PROGRAM TEST.

AXIS/DIRECTION SELECTION PUSHBUTTONS

X+ AXIS (Push Button with LED) (B9)

-- X

This push button is used for continuous axis jogging in the X+ direction. It is also used in the MPG mode for HANDWHEEL X axis selection where upon both X+ and X-- push buttons are illuminated.

X -- AXIS (Push Button with LED) (D9)

This push button is used for continuous axis jogging in the X-- direction. It is also used in the MPG mode for HANDWHEEL X axis selection where upon both X+ and X-- push buttons are illuminated.

Z+ AXIS (Push Button with LED) (C10)

This push button is used for continuous axis jogging in the Z+ direction. It is also used in the MPG mode for HANDWHEEL Z axis selection where upon both Z+ and Z-- push buttons are illuminated.

Z-- AXIS (Push Button with LED) (C8)

-- Z

Cincinnati Machine 91203597B001 Page 3--7

This push button is used for continuous axis jogging in the Z-- direction. It is also used in the MPG mode for HANDWHEEL z axis selection where upon both Z+ and Z-- push buttons are illuminated.

NOTE: X+, and Z+ pushbuttons also illuminate; in Auto or MDI mode

when the corresponding machine axes are sent to their alignment position using G28 and during the machine axes alignment sequence.

RAPID TRAVERSE (Push Button with LED) (C9)

This push button can be operated simultaneously with any power feed push button to producerapid axis jogging motion as long as the operator door is closed.

PARTS CATCHER DOWN (Push Button with LED) (A6)

(only active when the parts catcher option is fitted) This push button is used to jog the parts catcher down.

It is only active when not in cycle and with the operator door closed.

PARTS CATCHER UP (Push Button with LED) (A7)

(only active when the parts catcher option is fitted) This push button is used to j og the parts catcher up.

It is only active when not in cycle and with the operator door closed.

TURRET JOG + (INCREMENT) (Push Button with LED) (C4)

This push button is used to jog the turret in the clockwise (CW) incrementing count direction. (CW as viewed from spindle to turret).

Itisonlyactivewhennot incycle,operatordoor closed,spindleisstationary and the AUX 1 push button is pressed.

TURRET JOG -- (DECREMENT) (Push Button with LED) (C5)

This push button is used to jog the turret in the counter clockwise (CCW) decrementing count direction. (CCW as viewed from spindle to turret).

Itisonlyactivewhennot incycle,operatordoor closed,spindleisstationary and the AUX 1 push button is pressed.

CHUCK -- ID GRIP (Push Button with LED) (A8)

This push button is used to select ID gripping of the chuck. It is only active when not in cycle and the spindle is stationary.

CHUCK -- OD GRIP (Push Button with LED) (A9)

This push button is used to select OD gripping of the chuck.

Page 3--8

It is only active when not in cycle and the spindle is stationary.

OFFSET MEASURE (Push Button with LED) (A10)

Thispushbuttonisusedtosetoffsetsonthemachine. Refer to Fanuc manual for a full description of its use.

It is only active when not in cycle and the spindle is stationary.

Cincinnati Machine 91203597B001

TOOL SETTING ARM DOWN (Push Button with LED) (D2)

This push button is usedto jog the Renishaw ToolSetting Arm(TSA) to its down position -- Active position.

It is only active when not in cycle, operator door closed and the spindle is stationary.

TOOL SETTING ARM UP (Push Button with LED) (D3)

This push button is usedto jog the Renishaw ToolSetting Arm(TSA) to its up position -- Stowed position.

It is only active when not in cycle, operator door closed and the spindle is stationary.

PROGRAM RESTART (Push Button with LED) (D1)

This push button is currently not used.

AUX 1 -- Auxillary Push Button (Push Button with LED) (C6)

AUX

Used in conjunction with the Turret Jog + and Turret Jog -- push buttons.

COOLANT BUTTONS

COOLANT OFF (Push Button with LED) (F9)

This push button is used to manually turn the coolant flow off. It is functional in all modes. When selected during AUTO or MDI mode, M08 coolant on, is ignored.

COOLANT ON (Push Button with LED) (F8)

This push button is used to manually start the coolant flow and is activein all modes, provided that the operator access door is closed.

When selected during AUTO or MDI modes M09 coolant off is ignored. NOTE: Even if COOLANT ON is selected, the coolant flow is inhib-

ited during an automatic turret i ndex but will restart on completion of the turret index.

COOLANT AUTO (Push Button with LED) (F10)

This push button enables the coolant system to be controlled via coolant M codes.

It is only selectable in AUTO or MDI modes. NOTE: The COOLANT ON and COOLANT OFF push buttons can be

used during auto cycle, if COOLANT AUTO is to be overridden.

COOLANT AUTO is the default status when first selecting the AUTO or MDI modes and assumed at the end of every programme.

Cincinnati Machine 91203597B001 Page 3--9

The coolant flow is automatically turned off by: M00, M01, M02, M06, M09 and M30 codes, providing AUTO COOLANT is selected.

MISCELLANEOUS CONTROLS

MEMORY PROTECTION -- Keyswitch

This keyswitch is used to prevent part programs, offset values, parameters and setting data from being registered, modified or deleted accidentally.

This switch is enabled in all operating modes. The named functions are LOCKED OFF when the MEMORY PROTECTION KEYSWITCH is in the ON position.

RS 232 SERIAL DATA PORT

TheportcanbeusedtointerfaceanyRS232serialdata input / outputdevice via the machine m ounted 25 pin D--type female socket. See chapter 10 of this manual for set-- up and operational description of this facility.

100

FEED/RAPID/JOG OVERRIDE -- Selector Switch

This selector switch is used to override:

150

1. Programmed Feedrate (Outer S cale 0--150%) in AUTO & MDI mode. If an override could result in a feedrate greater than the maximum programmable feedrate, then the feedrate is clamped to that maximum value.

2. Rapid Traverse (Inner Scale 0--100%) in AUTO/MDI/JOG modes.

3. Jog rate (Inner Scale 0--100%) in JOG mode only.

Selecting the 0% graduation causes a feedhold condition except during a tapping cycle.

NOTE: Feed override is not possible whilst M 46, G63 or Tapping cycles

are active.

EMERGENCY STOP (red mushroom pushbutton with latch)

Pressing this pushbutton causes an immediate slide and spindle stop, followedbytheremovalofdrivepower. Thepushbutton remainsdepressed (latched) when actuated. Twisting the pushbutton in a counterclockwise direction releases the Emergency Stop button.

CAUTION

Actuatingthisbuttonwiththe machine in a cutting cycle may damage cutting tools and work pieces.

Failure to follow this instruction may resultin damageto equipment.

Page 3--10

The pushbutton is active at all times. See CAUTION.

Cincinnati Machine 91203597B001

MTB OPERATORS CONTROL PANEL

% SPINDLE LOAD

Master Start

Chuck P.B. Unclamp

0 25 50 75 100 150 180

Spindle Loadmeter

Cycle Start (duplicated)

Chuck P.B. Clamp

Tailstock Retract

Tailstock Advance/ Step Advance

Fig. 45 MTB Operators Control Panel

Spindle Load Meter

% SPINDLE LOAD

0 25 50 75 100 150 180

YellowBand 100 --150%

FANUC

Red Band 150 --180%

Fig. 46 Spindle Load Meter

The load meter is graduated in percentage load of the maximum output of the spindle motor.

0 to 100% Range (Continuous rating)

Providing the spindle load remains at 100% or less the machine spindle can be run continuously.

Cincinnati Machine 91203597B001 Page 3--11

110 to 150% Range -- Yellow Band (30 minutes 50% rating)

For every minute or part of a minute up to a maximum of 30 minutes, that the spindle load is in the 101 to 150% to range, there must either be an equivalent time period immediately following this overload when the spindle is in a NO LOAD condition, or a proportionally longer period of time when the load remains within the continuous operating range.

151 to 180% Range -- Red Band (1 minute overload capacity)

For any period of time up to a maximum of 1 minute the spindle load can enterthe151-- 180%overloadrange.Immediately afterthisperiodhowever the spindle must, for an equal period of time, be in a NO LOAD condition, or for a proportionally longer period of time, must stay within the continuous operating range.

NOTE: The above conditions are theoretical definitions and should only

be used as a guide.

In practice the spindle load is continuously varying and can therefore be difficult to estimate. As a general rule the spindle load should be kept as much as possible within the CONTINUOUS operating range with only occasional loadings being used within the 101 to 150% YELLOW BAND range.

CAUTION: The machine cycle should not take the spindle load into

the151 -- 180% RED BANDrangewhilstcuttingisbeing carried out. Only during acceleration of the spindle should the load meter go to the full scale deflection (RED BAND).

MASTER START -- Illuminated push button

This push button is used to power up the control and axis/spindle drives in a controlled sequence.

Depressing the master start push button will bring the CNC control power on in a control EMG condition.

Repressing MASTER START -- on receipt of successful control power on, will apply power to the spindle and axis drives, where upon the control removes the EMG status indicator.

The control will report an EMG ALM condition, if the Emergency Stop push button is depressed or if axes go into a hard OVERTRAVEL, or if any other alarm is active which results in the removal of servo control.

The MASTER START push button is also used in the event of a hardware axis overtravel, as it overrides the overtravel limit switches, whilst held depressed. The axis drive power is thus reinstated, enabling the axis to be jogged back, to within its normal operating range.

Page 3--12

CYCLE START

This duplicatedpush button has the identical function to thatof the CYCLE START push button (F1) on the operators control panel.

SeePage3--4.

Cincinnati Machine 91203597B001

HANDWHEEL (MPG)

FANUC

When MPG mode is selected, clockwise rotation of the handwheel will result in Positive axis motion and counterclockwise rotation will give Negative axis motion.

Axisselectionis performedbyusingtherelevantcontrolpanelpushbuttons. MPG mode and the distance per increment are selectable from the control

panel push buttons. Increments are:

0.001mm-- MPG x 1 pushbutton

0.010mm-- MPG x 10 pushbutton

0.100mm-- MPG x 100 pushbutton

Handwheel control of the machine axes (as described above) is possible when C--Axis Mode OFF (M50) is active. In this mode, the operator door maybeopenorclosedwhilstanaxisisinmotion.

In C--Axis Mode ON (M51 active), the handwheel may be used to control rotationof the spindle/chuck. Handwheelmode is selected by pressing one of the ’MPG Mode -- Distance/Increment’ push buttons on the operator panel. The Spindle CW or Spindle CCW push button must be pressed to engage the spindle/chuck; both CW and CCW button LED’s illuminate. Clockwise rotation of the Handwheel produces a clockwise rotation of the spindle/chuck as viewed from the +Z (tailstock) end of the machine.

CHUCK UNCLAMP push button

This push button unclamps the chuck. It is only active when not in cycle and with the operator door open. See NOTE 1 below.

CHUCK CLAMP push button

This push button clamps the chuck. It is only active when not in cycle and with the operator door open. See NOTE 1 below.

NOTE 1: The clamping/unclampingof the workpieceis determined

by the selection of ID/OD Grip.

WARNING Chuck Operation

Do not operate the chuck at speeds (rpm) greater than its maximumratedspeed or at pressuresgreaterthanitsmaximum rated pressure. Refer to machine mounted plate or chuck manufacturer. Reduce chuck speed (rpm) when using special top jaw tooling. Top jaws must not extend beyond the chuck diameter. Never place your hands or any part of your body near the chuck when jogging thespindle, adjustingthrust or pressure. Lubricate the chuck according to the manufacturer’s specifications. Use jaw serrations as noted on machine mounted plate or specified by chuck manufacturer. Failure to follow this instruction may result in serious personal injury.

Cincinnati Machine 91203597B001 Page 3--13

T AILSTOCK QUILL ADVANCE/STEP ADVANCE push button

This push button is used to advance the tailstock quill. It has two modes of operation:--

a) Operator door open -- Step advance -- Quill stops advancing when

pushbutton i s released. Quill is not held fully forward, i.e. Operator door must be closed and pushbutton pressed to “lock” the tailstock fully forward.

b) Operator door closed -- full advance -- Quill is held fully forward.

See WARNING.

T A ILSTOCK QUILL RETRACT push button

This push button is used to retract the tailstock quill. Operator door must be open for the tailstock to retract.

WARNING Tailstock Quill Step

Tailstock Quill Step Advancemust only be used forset--up purposes as pressure is not maintained in its static position. Failure to follow this instruction may result in serious personal injury.

Page 3--14

Cincinnati Machine 91203597B001

Machine Pressure -- Tailstock Thrust -- Chu ck Drawbar Force -- Chuck Brake (Dampener) Control

This control panel is located on the front of the machine to the left of the headstock and includes: main machine pressure gauge, tailstock thrust gauge and pressure control knob, chuck drawbar force gauge and pressure controlknob. A furtherpressure gauge and control knob is also supplied to adjust a chuck brake (dampener) when the C--Axis mode feature is present.

Machine Pressure -- The machine system operating pressure of 35 Bar is indicated on the uppermost gauge. This pressure is set by a regulating screw mounted on the top of the hydraulic system pump.

Machine Pressure Gauge

Tailstock Pressure Knob

Tailstock Pressure Gauge

Chuck Pressure Knob

Chuck Pressure Gauge

Fig. 47 Main Spindle Chuck & Tailstock Pressure

Tailstock Thrust -- The centrally located tailstock thrust gauge monitors

settings of the adjacent pressure regulating valve control knob. The maximum thrust is 7.86kN @ 35 Bar.

Whensetting thetailstockquillpressure, advancethequilluntil thetailstock center is engaged with the part, then adjust the valve until the desired pressure setting is obtained.

When setting a lower pressure, adjust the valve until the lower setting is obtained. Retract the quill then advance it again to check for the correct lower setting. If the pressure falls below 3 Bar before starting a cycle or during a cycle, the machine will stop and display the appropriate alert.

Chuck Drawbar Force -- The lower chuck drawbar force gauge monitors settings of the adjacent pressure regulating valve control knob. Chuck jaw grip force must be checked a every 200 hours (minimum) of operation.

The main spindle chuck pressure regulating valve controls the gripping forceof the main spindle power chuck. Use the maximum pressure setting unless the maximum pressure setting distorts the part.

The maximum force is 56.5kN @ 35Bar. Do not exceed the maximum pressure stamped on this plate. If higher pressure is selected, high stress forces are created within the chuck resulting in possible damage to the chuck. Check the chuck manufacturer’s sprcifications for maximum chucking pressures, maximum rpm and lubrication before using this control.

Check the clamping force with a Static Grip Clamping Force Gauge (force per jaw with spindle not running) and a Dynamic Grip Clamping Force Gauge (force per jaw measured with the spindle running).

NOTE: Use the maximum manufacturerapprovedchuck clampimg force

pressure that will result in minimum part distortion.

Chuck Brake (Dampener): C--Axis Interpolation Mode -- T h e purpose of this brake is to offer a degree of dampening to the cutting action when the spindle chuck is in C --Axis interpolationmode and miscellaneous code M53 is programmed. The minimum setting for the brake is 2 Bar.

CHUCK BRAKE PRESSURE GAUGE

The amount of dampening is adjustable by the user and will depend on the severity of the cutting process. Brake adjustment is via a regulating screw

Fig. 48 Chuck Brake Pressure (Option)

Cincinnati Machine 91203597B001 Page 3--15

along side the pressure gauge.

WARNING

Place the MAIN POWER DISCONNECT switch in the OFF position, lock it and tag it with a “DO NOT START”sign before servicing the machine or control.

Note: This switch does not isolate the incoming supply to the electrical cabinet or the supply to the Transformer Unit.

Failure to follow this in structioncanresultinmachine damage and personal injury.

MAIN POWER DISCONNECT SWITCH

See W ARNING

This switch is used to supply power to the machinesmain electrical cabinet and is located on the rear door of the electrical cabinet.

When the switch is in the ON position: power is supplied to the machine electrical cabinet.

Beforeservicing the machine or control, always place this switch in the off position. Lock and tag this switch with a “do not start sign”.

It is also important to wait for the condensers in the servo drives to be completelydischarged.AredLEDisfittedtoeach servo drivepower circuit PCB. The LED will remain illuminated whilst any charge remains in the condensers.

Page 3--16

Cincinnati Machine 91203597B001

Optional Operating Devices

Swarf Conveyor

The swarf conveyor unit is positioned across t he front of the machine with the outlet hood on the right side of the machine.

Fig. 49 Swarf Conveyor Control Panel

1. Conveyor Control AUTO/ ON MAN/OFF -- Selector Switch In AUTO selection, the chip conveyor will rotate continuously in its

normal clockwise direction when the operator door is closed and the machine is set in--cycle by pressing the CYCLE START push button.

NOTE: The conveyor will stop if,

6) The EMERGENCY STOP push button is pressed.

7) The Operator Door is opened.

8) The MAN/AUTO selector switch is set to MANUAL.

InMAN(manual)selection,the swarfconveyorwillremain stationary unless the conveyor direction selector switch is set to Forward or Reverse.

Cincinnati Machine 91203597B001 Page 3--17

2. CONVEYOR DIRECTION --Selector Switch (spring centered) This switch is a jog facility operative only when the conveyor

MAN/AUTO selector switch is set to MANUAL. With the conveyor direction switch held in the FWD (forward)

position, the conveyor will rotate in its normal clockwise direction; when held in the REV (reverse) position the conveyor will rotate in a counter--clockwise direction. When released, the switch will spring back to the OFF (center) position.

EMERGENCY STOP -- Push Button (Red Mushroom)

3. This push button i s pressed to immediately stop machine cycle and

operation in the event of an emergency. When this push button is pressed machine power drops, stopping the

feed of all axes and spindle. Control power will remain on and a messageisdisplayedonthecontrolCRT,“MACHINE OFF E--STOP.”

The EMERGENCY STOP must be released before the machine can be restarted. To release the button it must be twisted counter--clockwise.

IfEMERGENCY STOP is pressedwhile the axes arenot in motion an automatic realignment is possible when the button is released.

Wash Gun

The Wash Gun (if supplied) is used by the operator to flush swarf into the machine swarf collection tray, or swarf conveyorsystem (if supplied). The wash gun facility may be used when,

-- The machine is not in--cycle.

-- The operator door is open.

-- The Coolant ON push button is pressed ON.

The wash gun is active for a period of 30 seconds after which the Coolant ON push button must be pressed to restore the coolant supply to the wash gun.

Page 3--18

Cincinnati Machine 91203597B001

CAUTION

Always observe the general chuck safety guidelines in the daily operation of the machine. Failure to follow this instruction may result in damage to the machine.

GENERAL CHUCK SAFETY GUIDELINES

Observe these guidelines in the daily operation of the turning center. See CAUTION.

1. Always lubricate the chuck according to the instructions given in this manual or the chuck manufacturer’s instructions.

2. Clamp all work fixtures securely before starting the machine. When using work fixtures mountedin the chuck, usethe chuck jaws to center the fixture only. Clamp the fixture to the chuck face using the tapped holes and T--slots in the chuck face once the chuck jaws are secured about the fixture. If appropriate, remove the chuck and mount the fixture directly to the spindle.

NOTE: Do NOT place a chuck within a chuck already mounted to the

spindle.

3. Inspect the top jaws before starting any operation. In the event of a wreck, always replace the top jaw hold down bolts.

4. Always replace the T--nuts, which clamp the top jaws to the master jaws, at the first sign of wear.

5. Never use top jaws with worn or broken jaw serrations. On the first operation, always ensure that the jaw serrations penetrate the part.

WARNING

Never place your hands or any part of the body near the chuck when jogging the spindle. Failure to follow this instruction may result in serious personal injury.

6. Load the part in the chuck with one jaw in the 6 o’clock position.

7. Neverplaceyour hands or any portionof thebody,nearthe chuckwhen jogging the spindle. See WARNING.

Cincinnati Machine 91203597B001 Page 3--19

WARNING Chuck Operation:

Do not operate the chuck at speeds (rpm) greater than its maximum rated speed or at pressures greater than its maximum rated pressure. Reduce chuck speed (rpm) when usingspecialtop jawtooling. Top jaws must not extend beyond the chuck diameter. Never place your hands or any part of your body near the chuck when jogging the spindle, adjusting thrust or pressure. Lubricate the chuck according to the manufacturer ’sspecifications.

Failure to follow this instruction may result in serious personal injury.

CHUCKS

Since a variety of chucks may be mounted on the machine, the following information describes the general types of chucking systems that can be applied to the machine, top tooling recommendations, a general discussion ofchuckjawpressure, lubricationof chucksystemsandsome generalchuck safety guidelines.

CHUCKING SYSTEM TYPES

These four types of chucks are recommended for use on these machines. Self--centering -- simultaneouslymoves all chuckjaws equally to center the

workpiece in the chuck. Self--compensating -- used where there is a need to locate the workpiece

from center holes, or other locating devices. Combination -- combine both self--centering and self--compensating fea-

tures in one chuck. Collettype-- idealforbarstock, theyarecompatiblewithsquare,hexagonal,

and round shapes.

CHUCK

CENTRIFUGAL FORCE AND SPEED LIMITATIONS

CAUTION 1

Donotoperatethespindleat speeds greater than the maximum rated speed for the chuck. Failure to follow this instruction may result in damage to the chuck and machine.

CAUTION 2

Always reduce spindle speed when using special topjawtooling. Failuretofollow this instruction may result in damage to the machine.

CAUTION 3

Alwayslubricatethechuckin accordance with these instructions or follow the chuck manufacturer’sspecifications. Failure to follow this instruction may result in damage to the chuck and machine.

Centrifugalforceincreases as therpmincreases and tendsto throw thechuck jaws outward. This decreases the part gripping force.

Centrifugal force increases as the jaws aremoved farther fromthe centerline of the chuck, or are made heavier.

Exceeding a chuck’ srated speed results in high internal stresses and loss of clamping force. This can cause jaw and/or chuck component breakage resulting in the release of the jaw and part. See CAUTION 1.

Top jaws should never extend beyond the diameter of the chuck. Alwaysreducethespindlespeedwhenusingspecialtop jaw tooling config-

urations. See CAUTION 2.

CHUCK LUBRICA TION

Allchuckingsystemsrequiresometype oflubrication.Chucksmaybeself-lubricating,orrequiremanuallubrication.Ifmanuallubricationisrequired, follow the instructions in this section for standard chucks installed by the factory. For other chucks, follow the chuck manufacturer’s specifications for frequency and lubrication type.

Inadequate lubrication or use of the wrong type of lubricant will greatly reduce the chuck jaws grip force and allow the workpiece to slip or be thrown from the chuck.

If in doubt about the lubrication requirements for the chuck, contact your local Cincinnati Machine Field Service Representative. See CAUTION 3.

Factoryinstalled standard chucks that requiremanuallubrication should be lubricated once during every eight hours of operation.

Page 3--20

Cincinnati Machine 91203597B001

TOP JAW RECOMMENDATIONS

The following illustrations list general guidelines for designing and setting chuck top jaws.

1. The length of the top jaws should not exceed the height, and the height of the top jaw should not exceed the length of the master jaw.Do not exceed a 1:1 ratio.

2. The gripping diameter should be equal to, or greater than, the diameter to be machined. When this is not possible, reduce the feed rate and the depth of cut.

3. Grip the workpiece as close to the face of the chuck as possible.

CORRECT

CORRECT INCORRECT

INCORRECT

4. Use special jaws with a longer grip on large, long, or heavier workpiece.

5. Jaws should be designed so the diameter fully contracts the work-piece. Standard stepping top jaws seldom achieve this goal.

CORRECT INCORRECT

CORRECT

INCORRECT INCORRECT

Cincinnati Machine 91203597B001 Page 3--21

6. Use pin type jaws to penetrate forging, casting and irregular surfaces.

7. Use sharp 3.2 mm (.125 inch) pitch 60 degrees serrations on jaws for first operations.

8. The back of chuck jaws must be ground after hardening.

3.2 mm (.125”) 60_

60_

PIN (IN JAW BOLT HOLE)

9. Bore soft jaws with a chucking slug or ring under, or in front of, the top jaw. Do not bore with the slug or ring under the master jaws. The slug or ring should be as far as possible from the face of the chuck.

10. Check the top jaws for “bell mouthing”. This can cause the workpiece to move slightly under a heavy cut and cause the cutting tool to dig in. This can result in the workpiece being scrapped or the workpiece coming out of the chuck.

11. Reduce the chucking pressure approximately 10% for each inch exceeding 76 mm (3 inches) of jaws height to prevent breaking master jaws, levers, or wedges.

RING

SLUG

76 mm (3.0 ”)

Page 3--22

Cincinnati Machine 91203597B001

12. On second operation jaws, use chrome--moly steel such as 4140 or 4150. To strengthen these jaws and resist chipping, heat treat to 28--30 Rc. When necessary, they can be true bored.

13. On rough surfaces, use 8615 steel jaws to obtain greater core strength and to resist fracturing under heavy gripping pressure.

14. Use rocking jaws on rough castings or forgings.

15. Use wrap--around jaws on fragile parts to distribute pressure over a larger area and to minimize distortion.

ROUGH WORKPIECE

CHUCK

WRAPAROUND JAW

16. On wedge chucks, grip the workpiece

1.6 mm (.06”) from the start of jaw travel for best engagement of wedge with the master jaw.

17. On lever chucks, grip the workpiece past the middle of jaw travel for best gripping conditions.

18. Do not grip another chuck in the jaws of the chuck mounted to the spindle.

19. Although fixtures may be gripped in the jaws of chuck for center location, the jaws must be not be the sole mounting means. Bolt the fixture to the chuck.

FRAGILE PART

Cincinnati Machine 91203597B001 Page 3--23

Chapter 4 Machine Start Up and Alignment Procedure

Machine Start Up and Alignment Procedure General

Thissectiondescribestheoperationsrequiredtostartthemachineandalign the control to the machine.

Start Up and Shut Down Procedures Start Up

1. Ensure that the machine air supply is turned on and is up to pressure.

2. Ensure sufficient hydraulic oil is in the hydraulic tank.

3. Turn the main disconnect switch to the ON position.

4. Press the MASTER START push button on the MTB operator control panel.

This will apply power to the C NC and initiate a power start of the control. After a few seconds, onsuccessful control power upcondition, the CRT will flash t he EMG condition i ndicator.

CAUTION

Until the machine has been aligned it is possible to feed the axes beyond the authorized software feed limits. Thismayresultintheremovalofpowerto the axisdrives.

5. Re--press the MASTER START pushbutton. This will initiate a power--up sequence of the axes and spindle drives and apply power to the hydraulic unit. The EMG condition indicator is removed from the display. Caremustbetakenatthistime, if the axes are moved under powerfeed control, as there is no software range checking until the machine has been aligned. See CAUTION.

If the EMERGENCY STOP push button is latched down when the MASTERSTARTpushbuttonispressedinstep3theCRTwilldisplay EMG ’ALM 1002 EMERGENCY STOP’ alarm. Release the EMERGENCY STOP push button to clear the alarm.

IfanAXISOVERTRAVEL condition exists at the time of power--upusethe axis power feed controls whilst holding the MASTER START push button depressed, the move all axes within their normal operaating range -- see Chapter 5.

Shut Down

The normal safe shut down sequence is as follows:

1. Depress EMERGENCY STOP to ensure a controlled stop sequence of the axis drives and to turn off the hydraulic motor.

2. Set the main machine power disconnect switch to the OFF position.

Cincinnati Machine 91203597B001 Page 4--1

Machine/Control Alignment Procedure

The operator must perform a machine/control alignment, each time the control is turned on.

The slides and turret are aligned by using the ALIGN push button (A4) on the operator’s panel.

The automatic alignment procedure first moves each axis to its reference position, after which the linear axes are aligned to the control system by moving each axis a small distance to search for the axis motor encoder reference marker .

The axes are automatically moved to their reference position in a Z,X sequence. As each axis is aligned to the control system the corresponding axis powerfeedpush button is illuminated. Onceall active axes arealigned, the ALIGN push button can be released.

AXIS ALIGNMENT SEQUENCE AXES ALIGNMENT COMPLETE

INDICATION

Z+ PUSHBUTTON ILLUMINATES

X+ PUSHBUTTON ILLUMINATES

Turret Alignment

On completion of the machine axes alignment, the turret has to be aligned. This is achieved by repressing the ALIGN push button in response to the operatormessage:PRESS ALIGNP.B. TO REF TURRET. This will cause the turret to rotate to position 1.

Drive Tool Machines only

The operator message: DRIVEN TOOL SPINDLE NOT ORIENTATED -PRESS HOME PB TO ORIENTATE SPINDLE REFERENCE TURRET. Pressingthehomepushbutton willcausethedriventool spindle to orientate and the turret will then rotate to position 1.

Turret alignment must be completed with the X and Z axes at their extreme positive axis positions. See WARNING.

WARNING

Turret alignment can only take place with X and Z axes at their positive limits. The operatormust ensure that, at this position,turretrotationwillnotcause a collisionwith tooling or workpiece.

Page 4--2

On successful completion of axes and turret alignment, the ALIGN push button will illuminateand remain illuminated until themachineis switched off or an alert is posted which could result in the loss of alignment.

Cincinnati Machine 91203597B001

Chapter 5 Software and Hardware Axis Overtravel

Software Axis Overtravel

A software axis overtravel conditon occurs if an axis is commanded to go beyond its normal operating range, indicated by the following alarms:

500 OVER TRAVEL: +X 501 OVER TRAVEL: --X 500 OVER TRAVEL: +Z 501 OVER TRAVEL: --Z

During a software overtravel conditon, the control only permits the axis to move back from the software overtravel condition.

CANCELLING SOFTWARE RANGE CHECKING

It may sometimes be necessary to temporarily cancel the software range checking feature, to enable the axes to be powerfed back to within their normal operating ranges.

To cancel software range checking:

1. Turn the main power disconnect switch to the OFF position.

2. After a few seconds set the main power disconnect switch to the on position.

3. Depress and hold down both P and CAN keys on the MDI keypad.

4. Depress MASTER START to initiate a control power start.

5. Once control is powered up release P and CAN keys on the MDI keypad.

6. The software range checking is now ineffective and therefore it is possible to drive an axis beyond its software range limits.

Hardware Axis Overtravel

Prior to completion of machine alignment, it is possible to feed the axes beyondthe authorised software limits. This action may result in a servofail alarm.

Itwillbenecessary to usethe followingproceduretomovetheovertravelled axis back to within its normal operating range.

1. Trytoestablish the reasonwhytheovertravel condition occurred.Ifthe overtraveloccurredforno apparent reason check the general condition of the axis motor electrical connectors and cables. If the condion of these is good proceed with caution.

2. Power down control, isolator off.

3. Power back up control.

Cincinnati Machine 91203597B001 Page 5--1

4. Select MPG mode.

5. Using the MPG (handwheel) move the axes back within their normal operating range. The axis jog mode is disabled when the axes are not aligned.

Note: It may be necessary to supress the axis softwarelimits in order to

move the axes back into their normal operating range.

Page 5--2

Cincinnati Machine 91203597B001

GCODE

GROUPFUNCTION

A B C

Chapter 6 G codes

G codes

The following G codes are supported on the Cincinnati Machine range of lathes.

G--code of group 00 except G10 and G11 are single--shot G--codes. P/S alarm (no. 010) is displayed when a G--code not listed in the G--Code

list is specified or a G--code without a corresponding option is specified.

G code System A is set as standard.

G--code systems B and C are purchased options -- contact Cincinnati Machine if option is required.

Refer to FANUCManualB--63084 EN/01 for a complete description of the G Codes.

G00 G01 G01 G01 G02 G02 G02 G03 G03 G03 Circular Interpolation CCW or Helical interpolation CCW G04 G04 G04 G05 G05 G05 G07 G07 G07 00 Hypothetical axis interpolation

G07.1

(G107)

G10 G10 G10

G11 G11 G11 Programmable data input cancel

G12.1

(G112)

G13.1

(G113)

G17 G17 G17 XpYp plane selection G18 G18 G18 G19 G19 G19 YpZp plane selection

G00 G00 Positioning (Rapid Traverse)

Linear Interpolation (cutting feed) Circular Interpolation CW or Helical interpolation CW

Dwell High speed cycle cutting

G07.1

(G107)

G12.1

(G112)

G13.1

(G113)

G07.1

(G107)

G12.1

(G112)

G13.1

(G113)

Cylindrical interpolation Programmable data input

Polar coordinate interpolation mode

Polar coordinate interpolation cancel mode

ZpXp plane selection

G20 G20 G70 G21 G21 G71

G22 G23 G23 G23

Cincinnati Machine 91203597B001 Page 6--1

G22 G22

Input in inch Input in mm Stored stroke check function on

Stored stroke check function off

GCODE

GROUPFUNCTION

A B C

G25 G25 G25 G26 G26 G26

Spindle speed fluctuation detection off

Spindle speed fluctuation detection on G27 G27 G27 Reference position return check G28 G28 G28 G30 G30 G30

Return to reference position

2nd, 3rd and 4th reference position return G31 G31 G31 Skip function G32 G33 G33 G34 G34 G34 G36 G36 G36 G37 G37 G37

Thread cutting

Variable--lead thread cutting

Automatic tool compensation X

Automatic tool compensation Z G40 G40 G40 Tool nose radius compensation cancel G41 G41 G41

Tool nose radius compensation left G42 G42 G42 Tool nose radius compensation right G50 G92 G92

G50.3 G92.1 G92.1 G50.2

(G250)

G51.2

(G251)

G50.2

(G250)

G51.2

(G251)

G50.2

(G250)

G51.2

(G251)

G52 G52 G52

Coordinate system setting or max. spindle speed setting

Workpiece coordinate system preset

Polygonal turning cancel

Polygonal turning

Local coordinate system setting G53 G53 G53

Machine coordinate system setting G54 G54 G54 Workpiece coordinate system 1 selection G55 G55 G55 Workpiece coordinate system 2 selection G56 G56 G56 G57 G57 G57

Workpiece coordinate system 3 selection

Workpiece coordinate system 4 selection G58 G58 G58 Workpiece coordinate system 5 selection G59 G59 G59 Workpiece coordinate system 6 selection G65 G65 G65 00 Macro calling G66 G66 G66 G67 G67 G67 G68 G68 G68 G69 G69 G69

Macro modal call

Macro modal call cancel

Mirror image for double turrets ON or balance cut mode

Mirror image for double turrets OFF or balance cut mode cancel

G70 G70 G72 Finishing cycle G71 G71 G73 Stock removal in turning G72 G72 G74 Stock removal in facing G73 G73 G75

Pattern repeating G74 G74 G76 End face peck drilling G75 G75 G77 Outer diameter/internal diameter drilling G76 G76 G78 Multiple threading cycle

Page 6--2

Cincinnati Machine 91203597B001

GCODE

GROUPFUNCTION

A B C

G80 G80 G80 Canned cycle for drilling cancel G83 G83 G83 Cycle for face drilling G84 G84 G84 Cycle for face tapping G86 G86 G86

Cycle for face boring G87 G87 G87 Cycle for side drilling G88 G88 G88 Cycle for side tapping G89 G89 G89 Cycle for side boring G90 G77 G20 Outer diameter/internal diameter cutting cycle G92 G78 G21

Thread cutting cycle G94 G79 G24 Endface turning cycle G96 G96 G96 G97 G97 G97 G98 G94 G94 G99 G95 G95

-- G90 G90

-- G91 G91

-- G98 G98

-- G99 G99

Constant surface speed control

Constant surface speed control cancel

Per minute feed

Per revolution feed

Absolute programming

Incremental programming

Return to initial level (See Explanations 6)

Return to R point level (See Explanations 6)

Assumed at Control Power ON.

Cincinnati Machine 91203597B001 Page 6--3

Chapter 7 M codes

M codes

Miscellaneouscodes are programmed using a maximum of one M code per block with a value range of 0 to 99.

These codes are used to control a variety of machine related functions, including spindle, coolant and tool change.

M codes supported on Cincinnati Turning Centres

M codes marked thus * are availableas options or are necessary to support optional machine configurations, eg: Parts Catcher, Barfeed, etc.

M codes m arked thus * support the Driven Tool option, if fitted.

MCODE

00 PROGRAM STOP 01 OPTIONAL PROGRAM STOP 02 END OF PROGRAM 03 START SPINDLE CCW 04 START SPINDLE CW 05 SPINDLE STOP 08 COOLANT START 09 COOLANT STOP 13 SPINDLE START CCW WITH COOLANT 14 SPINDLE START CW WITH COOLANT 19 ORIENTED SPINDLE STOP 30 END PROGRAMME & RETURN TO START 34 * PARTS CATCHER ADVANCE 35 * PARTS CATCHER RETRACT 44 * RENISHAW TOOL SETTING ARM (TSA) UP 45 * RENISHAW TOOL SETTING ARM (TSA) DOWN 46 FEEDRATE OVERRIDE DISABLE (100%) 47 FEEDRATE OVERRIDE ENABLE 48 SPINDLE OVERRIDE DISABLE (100%) 49 SPINDLE OVERRIDE ENABLE 50 ** C--AXISMODEOFF 51 ** C--AXISMODEON 52 ** C--AXIS BRAKE ON (IN--POSITION MODE) 53 ** C--AXIS BRAKE ON (INTERPOLATION MODE) 54 ** C--AXIS BRAKE OFF

FUNCTION

EFFECT1VE

START OF

SPAN

EFFECTIVE

AT END OF

SPAN

n n

n n n

n n n n n

n n n n n n n n n n n n n n n n n n n

ASSUMED

ATCONTROL

POWER ON

Cincinnati Machine 91203597B001 Page 7--1

MCODE

FUNCTION

EFFECT1VE

START OF

SPAN

EFFECTIVE

AT END OF

SPAN

ASSUMED AT

CONTROL

POWER ON

61 * BARFEED MACRO CALL 68 * ADVANCE TAILSTOCK QUILL 69 * RETRACT TAILSTOCK QUILL 70 * M70 CUSTOMER OUTPUT 71 * M71 CUSTOMER OUTPUT 72 * M72 CUSTOMER OUTPUT 73 * M73 CUSTOMER OUTPUT 74 COLLET CHUCK MODE DISABLE 75 COLLET CHUCK MODE ENABLE 76 FORCE TURRET ROTATION CW 77 FORCE TURRET ROTATION CCW 78 RELEASE CHUCK JAWS 79 GRIP CHUCK JAWS 80 * BARFEED EJECT/RELOAD NEW BAR 86 * BARFEED PRESSURE ON (HYDRAFEED AND FEEDMASTER ONLY) 87 * BARFEED PRESSURE OFF (HYDRAFEED AND FEEDMASTER ONLY) 90 * BARFEED MODE ON 91 * BARFEED MODE OFF 92 * BARFEED ROTATION ON 93 * BARFEED ROTATION OFF 94 * INCREMENT PAR TS COUNTER (Parameter 6710 = 94) 98 SUBROUTINE CALL 99 END SUBROUTINE

n n n n n n n n n n n n n n n n n n n n n n n n

Page 7--2

Function Description of M Codes

M00 PROGRAMME STOP (STOPS SPINDLE)

M00 stops the machine cycle at the END of the block in which it is programmed. The spindle and coolant are stopped and the machine put out ofcycle.PressingCYCLESTARTwill causetheNCcycleto continuefrom the next block, restarting the spindle and coolant if previously actioned.

M01 OPTIONAL PROGRAMME STOP (STOPS SPINDLE)

M01 has the samefunction as M00 exceptit is only actioned i f the operator has selected the OPTIONAL STOP feature to be active. If the feature is not active the programme continues without actioning the M01.

M02 END OF PROGRAMME

M02 causes the active programme to terminate and the spindle and coolant to stop.

Cincinnati Machine 91203597B001

M03 START SPINDLE CCW

Note: CCW as viewed from Tailstock to Headstock M03 i s used to start the spindle rotation in a counter clockwise direction.

The spindle will rotate at the last programmed S word value. If the code is programmed in a block containing a none rapid traverse axis motion, then motion is inhibited until the spindle is up to speed. If the current block is a rapidtraverseblock the motion willcontinueuntilanonerapidblockisread with the spindle not yet at the programmed speed.

M04 START SPINDLE CW

Note: CW as viewed from T ailstock to Headstock M04isusedto start thespindlerotationin a clockwisedirection.The spindle

will rotate at the last programmed S word value. If the code is programmed in a block containing a none rapid traverse axis motion, then motion is inhibited until the spindle is up to speed. If the current block is a rapid traverseblockthe motion will continue until a none rapid block is readwith the spindle not yet at the programmed speed.

M05 SPINDLE STOP

M05 is used to stop the spindle. It causes further processing of axis moves or other blocks to be inhibited, until the spindle is stopped.

M08 FLOOD COOLANT START

M08 is used to tun on the flood coolant flow. There is no interlocking between the code and block processing, the programmer must allow sufficient feed stoke to assure adequate coolant flow before cutting starts. If dry run is active then this code is inhibited.

M09 COOLANT OFF

M09isusedtoturnthecoolantoff.

M13 STARTSPINDLE COUNTER CLOCKWISE WITH COOLANT

M13 is used turn on the flood coolant flow and start the spindlein t he CCW direction simultaneously.

M14 START SPINDLE CLOCKWISE WITH COOLANT

M14 is used turn on the flood coolant flow and start t he spindle in the CW direction simultaneously.

M19 ORIENTED SPINDLE STOP

Thiscodestopsthe spindle/chuckandturnsoffthecoolant. The codeforces the spindle to stop at a preset ’orient position’ and inhibits further block processing until orientation is complete. M19 is operable when C--Axis Mode OFF (M50) is active. In certain instances, the oriented spindle stop may facilitate the loading and unloading of workpieces.

M30 END OF PROGRAM AND REWIND

M30 terminates the active programme, stops the spindle and coolant flow, and returns the cursor back to the start of the programme.

Cincinnati Machine 91203597B001 Page 7--3

cincinnati C5000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

OPERATING/PROGRAMMING SUPPLEMENT

FOREWORD

Table of Contents

Chapter 1 Safety Precautions

Important

General Safety Instructions And Considerations

Personal Safety

Work Area Safety

T ool Safety

Lifting And Carrying Safety

Installation And Relocation Safety

Setup And Operation Safety

Maintenance Safety

Materials Used With This Product

LIFTING DEVICES

GENERAL

EYEBOLTS

HOIST RINGS

SPREADER BARS AND LIFTING BEAMS

CHAIN

CABLE SLINGS

SYNTHETIC MATERIAL SLINGS

P TYPE HOOKS

S HOOKS

U TYPE HOOKS

GENERAL SAFETY LIFTING INFORMATION

Fluids Used With Machine Tools

General Considerations

Lubricants

Cutting Fluids

Sources Of Information -- USA

Usage Information

Cutting Fluids -- Preventative Maintenance

SeeCautions1and2

Water Quality

Too Soft

Too Hard

Cleaning The Coolant Reservoir

Lifespan

Tramp Oil

Filtering

Rust Prevention

Printed Circuit Board Handling Instructions

General

Recommended Handling Procedure

Safety Features

Perimeter Guarding

Operator Sliding Door(s)

Feed Hold Push Button

Emergency Stop Push Button

Electrical Isolation Device (Main Disconnect Switch)

Air Supply Isolation Valve

Metric Lifting Points

Machine Related Safety And Usage Notes

Axis Overtravel Condition

Safe Operation Of Lathe Chucks

Work Holding Devices

General Operation

Battery Replacement

Lithium Batteries

Chapter 2 System Information

Introduction

Guard Strength

Noise

Fumes And Coolant Misting

Fire Hazard

NC Control

Machine Information

Axis Orientation

Hawk Specification

Machine And Range Drawings

Motor Rating

MACHINE ALIGNMENT AND PROGRAM POINTS

MACHINE ZERO

Chapter 3 Functional Description of Controls

Introduction -- GE FANUC 21i--TA CNC System