Kerney & Trecker AC, CH, &, CHL OperatorsManual

7/27/2019 Kerney & Trecker AC, CH, &, CHL OperatorsManual

1/27

MODEL ACPlain and Swivel Head Vertical Milling Machines

with mono lever nd automatic cycle t ble control3hp No.1 3hp No.2MODEL CH MODEL, CHL

Plain - Universal Swivel Head Vertical Milling Machineswith st nd rd directional t ble control

5hp No.2MODEL CHPlain -Universal Vertical Milling Machineswith mono lever nd with standard directional

automatic cycle t ble control t ble control


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Catalog No. CHC-11.

OPERATOR S MANUAL

3hp 18 - 24MODEL AC

Plain and Swivel ead Vertical Milling Machineswith mono-lever and automatic cycle table control

3hp No. 1 3hp No.2MODEL CH MODEL CHL

Plain Universal Swivel ead Vertical Milling Machineswith standard directional table control

5hp No.2MODEL CH

Plain Universal Vertical Milling Machineswith mono-lever and with standard directional

automatic cycle table control table control

illing achines

One copy of this manual is furnished with eachnew machine. Addit ional copies may be obtainedby writing direct to Kearney & Trecker Corporation.

Cop)'fl9Mf 1953

Kearney & TreekerCorporation

Milwaukee 14, WisconsinU s A.


3/27

SECTION PAGE SECTION PAGEELECTRICA L SYSTEM 12 IV CONVENTIONA L OPERATION (cont)Rapid Traverse Control. 15

n LUBRICATION SYSTEM 12 Trip Dogs and Limit Stops 15Desc ription . 12 Clamps 15Instructions. 12 Micrometer Stop Rods 15Speed and Feed Charts 16

III COOLANT SYSTEM Arbor Supports and Arbors. 16Description. 13 Overarms . 16Instructions 13 Outer Arm Brace 16Pulley Belt Adjustment . 16

IV CONVENTIONAL OPERATIONGeneral 1313 V AUTOMATIC CYCLE OPERATION 17Spindle Control. 13 Mono- Lever Control of Table. 17Automatic Spindle Stop. 13 Rate Selector Knob 18Spindle Reverse Control 14 Handwheel Control of Table. 18Spindle Speed Change Control 14 Knee, Saddle and VerticalSpindle Speed Range Control Head Control. 18(2CH Vertical Only) . 14 Plain Cycle Rapid TraverseCoolant Pump Control 14 Return 18Power Feed Controls 14 Intermittent Cycle - RapidHand Feed Controls 14 Traverse. 19Micrometer Dials 14 Continuous Cycle - RapidPower Feed Change Control. 15 Traverse. 19

LIST OF ILLUSTRATIONSFIGURE PAGE FIGURE PAGE

1. 1CH and 2CHL Universal Machines - 12. Mono-Lever Positions. 18Left Front View 4 13. Plain Cycle - Rapid Traverse2. 1CH and 2CHL Universal Machines Return Right to Left . 19

Right Front View. 5 14. Plain Cycle - Rapid Traverse3. 2CH Universal Machine - Left Return - Left to Right . 19Front View. 6 15. Intermittent Cycle - Rapid Traverse4. 2CH Plain Machine - With Mono-Lever Return - Right to Left . 19and Automatic Cycle Table 16. Intermittent Cycle - Rapid TraverseControl - Right Front View. 7 Return Left to Right 195. 2CH Vertical Head - Left and Right 17. Continuous Cycle RapidFront Views 8 Traverse 196. lCH, 2CHL, 18" - 24" AC Swivel Head 18. Lubrication Chart - 1CH, 2CHL,Vertical - Left and Right Front Views 9 18 - 24" AC Plain and Vertical7. 18" - 24 AC Plain Machines - Left Machines 20Front View. 10 19. Lubrication Chart - 2CH Plain8. 18 24" AC Plain Machines - Right Machines 21Front View. 20. Lubrication Chart 2CH Vertical9. Use of Table Dogs. 15 Machines 2210. Automatic Cyc Ie Controls - 2CH 21. Rules for Determining Speeds andMachines 17 Feeds 2311. Automatic Cycle Controls - 18" 24" 22. Guide to Correct Speed e l e t i o n 24AC Machines. 17 23. Guide to Correct Feed Selection 25

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FOREWORD

This manual contains instructions for operating theplain, universal and swivel head vertical styles of thefollowing Kearney & Trecker Milwaukee milling machines:

3 hp No.1 Model CH3 hp No.2 Model CHL3 hp 18 - 24 Model AC5 hp No. 2 Model CHThis manual has been prepared to familiarize you

with these machines and to help you operate them properly. The first three sections of the manual briefly describethe electrical, coolant and lubrication systems. Section IVdescribes conventional operation in which table travel ismanually controlled by the table feed lever. Section Vdescribes automatic cycle operation (on 18 - 24 AC and2CH machines only) in which table travel is automaticallycontrolled by trip dogs and the hydraulic system.

NOTETHIS IS AN OPERATOR'S MANUAL ONLY. or installation instruc

tions refer to the Installation Manual No.CHI-ll. or replacement partsinformation refer to Catalog CHR-31 for 1CH, 2CHL and 18 - 24 ACmachines and to Catalog CHR-33 for 2CH machines.

Figures 1 through 8 identify the units withwhich the operator should be familiar. Referto these illustrations when studying the manual.Check the figure title to be sure that the pictureillustrates the machine you are operating.

All references to the machine such as right and left,front and rear, etc. are made from the operator's normal position while f c i n ~ ~ tr:e 'TJachine.

t is our intention to continually improve the serviceyou receive from Kearney & Trecker - Milwaukee millingmachines and to make their operation as simple as possible.In accordance with this policy, we invite you to bring anyquestions and problems to the attention of the ServiceDepartment, Kearney & Trecker Corporation, Milwaukee14, Wis::onc;in, U.S.A. For service by telephone, callGR.;enfic:ld 6-8300.

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Operator s ManualNo.1 Model CH - 3hp No.2 Model CHL - Shp No.2 Model CH Plain - Universal Vertical3hp 18 - 24 Model AC Plain - Vertical Kearney & Trecker - Milwaukee Milling Machines

START ANDSTOP BUTTONS

COLUMN ilFLOW GAUGE O

SPEED SElECTION OUTER ARMKNOB BRACE

LEFT HAND ~ ' J ~ = n i - * i = - : : , . . . . . . COOLANT DISTRIBUTORTABLE BRACKET NOZZLES

RIGHT HANDTABLE TRIP DOGS

COLUMN OILSIGHT GAUGE LEFT HAND

TABLE TRIP DOGSTABLEHANDWHEEL ~ 1 SADDLE OIL

SIGHT GAUGE

MAINDRIVE KNEE FEED

MOTOR LEVER

KNEE CLAMP LEVER

Fig. 1 lCH and 2CHL Universal achines-Left Front View

BUILDERS OF PRECISION AND PRODUCTION MACHINE TOOLS FOR MILLING AND BORING


6/27

Operator s Manual .3hp No. I Model CH - 3hp No.2 Model CHL - 5hp No.2 Model CH Ploin - Universol-Verticol3hp IS o 24" Model C Plain - Vertical e ~ r n e y Trecker - Milwaukee ,illinl} Machin_e_s __

OVERARMSSTYLE A AND 'BARBOR SUPPORTS OVERARM CLAMP NUTS

STARTING LEVER. . . . . . ~ = \ ; ; ; ; ; . -

RBOR SUPPORT RIGHT HANDTABLE BRACKETLOCK NUTS

ARBOR SUPPORT MACHINE PULLEYOIL LEVEL GAUGE

TABLE CLAMP

TABLEFEED LEVER

KNEEHAND CRANK

Ii

SWIVEl

RAPID TRAVERSE MOTOR V BELTSLEVER

TElESCOPIC COOlANT MOTOR BASERETURN TUBE RIGHT ADJUSTING SCREWCOOLAt-lT PUMP

Fig. 2. lCH and 2CHL Universal Machines-Right Front View

BUILDERS Of PRECISION AND PRODUCTION MACHINE TOOLS FOR MILLING AND BORING


7/27

Operator s Manual3hp No.1 Model CH 3hp No.2 Model CHL 5hp No.2 Model CH Plain Universal Vertical

3hp IS , 24 Model C Plain Vertical Kearney Trecker Milwaukee Milling Machines

STYLE '"B"START AND INTERMEDIATESTOP BUTTONS ARBOR SUPPORT

LEFT HAND STYLE "B"OUTERARBOR SUPPORT

OUTER ARM BRACE

" , LEFT HANDt (PEED SELECTION TABLE TRIP DOGKNOB ELECTRICAL -------.. ' -

STARTER CABINET~SPINDLE REVERSE IKNOB - - r - - - ~

COLUMN OIL 1 / ..SIGHT GAUGETABLEHANDWHEEL

IT" ~SADDLE FEED

LEVER

MAINDRIVE

MOTOR

MOTOR BASE CLAMP LEVERLEFT ADJUSTING SCREW

SADDLE TRIP DOG

Fig 3 2CH Universal Machine Left Front View



8/27

Operator s Manual3hp No.1 Model CH - 3hp No.2 Model CHL - 5hp No.2 Model CH Plain - Universal-Verticallhp IS", 24" Model C Plain - Vertical Kearney Trecker - Milwaukee Milling Machines

STARTING LEVER COOLANT DISTRIBUTORSUPPORTARBOR SUPPORT

LOCK NUT OVERARMSOVERARM CLAMP NUT5

STYLEARBOR DRAW-IN BOLT

ARBOR SUPPORT ACHINE PUllOIL LEVEL GAUGE RIGHT HAND

TABLE BRACKET

SADDLE _ ::KNEE

HAND CRANK\

MOTOR BASERIGHT ADJUSTING SCREW

Fig. 4. 2CH Plain Machine-With MonoLever andAutomatic Cycle Table Control- Right Front View

BUILDERS OF PRECISION AND PRODU TION MACHINE TOOLS FOR MILLING AND BORING


9/27

Operator s Manual3hp No. I Model CH 3hp No.2 Model CHL 5hp No.2 Model CH Plain Universal- Verti(al

3hp 18 24 Model C Plain Verti(al Kearney Tre(ker Milwaukee Milling Ma(hines

HEAD LOCKINGNUT ARBOR

STARTING LEVERDRAWIN BOLT

HEAD CLAMP HEADLEVER

START ANDSTOP BUTTONS

COLUMN OILFLOW GAUGE

SPINDLE SPEEDRANGE CONTROL

HEAD OIL SIGHTAND FLOW GAUGE

PRECISION PRECISION STOPSTOP SCREW RATCHET LEVER

LOCKHEAD LOCKING NUTS.. ./

DISTRIBUlOR

VERTICAL HEADHANDWHEEL

VERTICAL HEADFEED LEVER

VERTICAL HEADTRIP DOG

COOLANT DISTRIBUTORSUPPORT ROD

COOLANT DISTRIBUTORNOZZLE

Fig 5 2CH Vertical Head-Left and Right Front Views

BUILDERS OF PRECISION AND PRODUCTION MACHINE TOOLS FOR MILLING ND BORING


10/27

Operator s Manual3hp No 1 Model CH - 3hp No 2 Model CHL - 5hp No 2 Model CH Plain - Universal-Vertical3hp 18 - 24 Model AC Plain - Vertical Kearnev . Treeker - Milwaul


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Operator s Manual3hp No.1 Model H - 3hp No.2 Model HL - Shp No.2 Model H Plain - Universal- Vertical3hp 18" 24" Model A Plain - Vertical Kearney & Trecker - Milwaukee Milling Machines

START ANDSTOP B U T T O N S ~ ~ O O l A N T DISTRIBUTOR

{ ~ ~ , NOZZlESCOLUMN OILFLOW GAUGE a , x- - ' ~ L- L ~ ~ ,, ,I ~EFT HANDTABLE BRACKET 1',' f !A 1

SPEED SELECTIONKNOB

SPINDLE R E V E R s ~ t 1 t JKNOB ~ f l . ~ ta...ElECTRICAL . ~STARTER CABINET . ~ . ,

' .3 ~ ~ .,

COlUMN OIL \. ~ ;'SIGHT GAUGE . . . , ~ : ~ { , .;

,I \ . .T B L E ~ J !HAND C R N K ~

SADDLE FEEDLEVER

FEED SELECTIONLEVER AND KNOB

MOTOR BASELEFT ADJUSTING SCREW

MAIN KNEE CLAMP BIJUR PUMPDRIVE LEVERMOTOR KNEE OIL

KNEE TRIP DOG SIGHT GAUGE

Fig. 7. 18" -24" AC Plain Machines - Left Front View

BUilDERS OF PRECISION AND PRODUCTION MACHINE TOOLS FOR MILLING AND BORING0


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Operator s M anual3hp No, I Model CH - 3hp No, 2 Model CHL - Shp No.2 Model CH Plain - Universal-Verti al3hp IS 24 Model C Plain - Verti 1I1 Kellrnev &Trecker - Milwllukee Milling Mllchines

OVERARMSOVERARM ClAMP NUTS

STARTING LEVER ~ARBOR SUPPORT

LOCK NUT -STYlE B' \\ .

INTERMEDIATE s.,..;ARBOR SUPPORT -r,r MACHINE PULLEY> . f .ARBOR S U P P O R T ~OIL LEVEL GAUGE , }. j ... ...

.... .. . RIGHT HANDTABLE ClAMP TABLE BRACKETLEVER

..

~ \KNEE

HAND CRANKSADDLE HANDWHEEL

MOTOR BASERIGHT ADJUSTING SCREW

COOlANT PUMPTELESCOPIC COOLANT MOTOR V BELTSRETURN TUBE

Fig. 8. 18"-24" AC Plain Machines Right Front View



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Operator s Manual3hp No.1 Model CH - 3hp No.2 Model CHL - Shp No.2 Model CH Plain - Universol- Vertical3hp 18 24 Model C Plain - Vertical Kearney Trecker - Milwaukee Milling Machines

SE TION I

ELECTRIC L SYSTEMThe electrical system consists of the main drivemotor and the necessary controls. This motor drives

the spindle and supplies power for the feed and rapidtraverse drives to knee, saddle, and table on allmachines and to the vertical head on sliding head vertical machines.A master disconnect switch which controls all current from the main line to the electrical startercabinet is actuated by a lever on the cabinet. The levermust bE in the ON position before power operation is

possible. The master start and stop buttons control themain drive motor. This motor must be runningin order to move the knee, saddle, table and verticalhead by power.

Control fuses, heater elements and overload relay:are incorporated in the electrical system to provide th('maximum protection for the motor and controls. BC -cause of the complexity of the electrical system,recommend that only a competent electrician be permitted to work on any of the equipment.

SE TION II

LUBRIC TION SYSTEMDESCRIPTION

There are individual lubricating systems for themoving parts of the column, the knee, the saddle, andthe vertical head. Each system is provided with asight gauge to indicate the oil level. The gauges forthe knee (plain machines only) and head also indicatewhether or not oil is flowing. The column is providedwith an individual flow gauge. Oil flows in the columnand knee systems whenever the motor is running. Oilflows in the vertical sliding head system wheneverthe spindle is running. The saddle system is operatedmerely by withdrawing and releasing the handle of theBijur pump.INSTRUCTIONS

1. Follow all directions given in the LubricationCharts on pages 20, 21 and 22.

2. Periodically check the oil sight g,lUges. Tnoil should be at the high point in the levei g. l ; ( lwhen the machine is not in operation and shouH1drop during operation. If oil is not paSSing throughthe flow gauges during operation, stop the motor incheck the oil level.

Note Oil flow does not register in theknee oil sight gauge on automatic

cycle machines.

3. Wipe the accumulated dirt from the exposed sections of the overarms and apply a thin coat of oilonce each day.4. Periodically grease the motor i f i t is providedwith two zerk fittings. If the motor is equipped withsealed-for-life bearings, refer to the manufacturer srecommendations.

12 BUILDERS OF PRECISION AND PRODUCTION MACHINE TOOLS FOR MILLING AND BORING


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Operator s Manual3hp Nt . 1 Model CH - 3hp No.2 Model CHL - 5hp No.2 Model CH Plain - Universal- Verti(al3hp 18 24 Model C Plain - Vertical Kearney Trecker - Milwaukee Milling Machines

SECTION III

COOLANT SYSTEMDESCRIPTION

The coolant pump distributes coolant from thereservoir in the base of the column up through pipesand nozzles to the cutter. From here the coolant fallsto the table and returns to the reservoir through thetelescopic coolant return tube. The coolant distributornozzles (two on the horizontal machines and one on thevertical machines) can be swiveled to distribute theflow to all types of cutters and are equipped with valvesfor regulating the coolant flow. The distributor canbe attached to either overarm on horizontal machinesby means of the coolant distributor support. When usedon vertical machines the distributor is mounted on asupport rod with a compound adjustable clamp. A

similar rod is used to hold the distributor when itnot in use.INSTRUCTIONS

1. Keep the screen covers on the two openingsthe column base when the machine is used withocoolant.2. Periodically remove and clean the screensthese pockets.

3. Use light cutting oils or soluble oil mixturethey are equally as efficient as heavy oils.4. Periodically check the level of coolant in threservoir. Fill the reservoir by removing the coveand adding coolant until the level rises to the screen

SECTION V

CONVENTIONAL OPERATIONGENERAL

This section describes conventional operation (inwhich the travel of the table is manually controlled bymeans of the table feed control lever) of the plain,universal and vertical machines. See Section V, page17 for automatic cycle operation with the mono-lever.Operation of plain and universal machines is identicalexcept in applications which require swiveling of thetable. For such applications the table on universalmachines can be swiveled approximately 47 degrees ineither direction from the normal position. The tablecan be locked in po sition with five clamp screws on the2CH machines - two on each end of the saddle and oneon the front. Four clamp screws are used on the lCHand 2CHL machines.Instructions for using the dividing head and leadattachments in spiral milling and indexing operationswill be found in catalog UHS-10.The main drive motor must be running before anypower movement is possible. To start this motor, seethat the lever on the electrical starter cabinet is setto the ON position, then push the master start button.Be sure to push the master stop button whenever themachine is not to be used for some time.SPINDLE CONTROL

The spindle is controlled by means of the startinglever. On horizontal and swivel head vertical machines

the spindle is started by moving the lever to the leand on sliding head vertical machines by moving thlever upward. To stop the spindle, move the startinlever in the opposite direction. The lever on horizontand swivel head vertical machines can be placedany position through a 300-degree arc merely braising t at the hub, rotating it to the desired positiand then lowering it into place. The lever on slidinhead vertical machines can also be located convenientfor the operator by removing it at the hub and replaCinit on the serrations as desired.

AUTOMATIC SPINDLE STOPThe 18 -24 AC and 2CH machines can be equippe

with a control which automatically stops the spindduring rapid traverse table movements and autmatically starts the spindle at the start of table feein automatic cycle operation. This control, callthe automatic spindle stop, is located on the speegear box. The spindle will start and stop automaticalwhen the knob on the automatic spindle stop is placein the ON position. The spindle will run continualwhen the knob is in the OFF position. When usinthe automatic spindle stop, disengage the starting levat the hub and lock t in the disengaged position withe thumb screw provided. This will prevent movment of the starting lever whenever the spindstarts or stops in automatic cycle operation.

BUILDUS OF PRECISION AND PRODUCTION MACHINE TOOLS FOR MILLING AND BORING


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Operator s Manual3hp No 1 Model CH - 3hp No 2 Model CHL - Shp No 2 Model CH Plain - Universal- Vertical3hp 18 24 Model C Plain - Milling Machines

SPINDLE REVERSE CONTROLThe direction of spindle rotation can be reversedas follows:1. Stop the spindle. Jog the spindle with the startinglever and push or pull the reverse knob for the desired

rotation. Do not reverse the rotation while the spindleis running.2 To disengage the drive to the spindle set theknob to the center or neutral position.SPINDLE SPEE CHANGE CONTROL

The spindle speed is changed as follows:1. Stop the spindle and withdraw the speed selectionknob on the speed gear box. Do not change speed whilethe spindle is running.2 Rotate the lever and knob until the desired speedas shown on the speed selection dial lines up with theRP M plate. Do not use force in rotating the lever. Jog

the spindle with the starting lever while rotating thelever if the lever does not rotate freely.3. Insert the knob plunger in the hole provided tolock the lever in position.SPINDLE SPEE RANGE CONTROL(2CH VERTICAL ONLY)

The range of spindle speeds is indicated on thespeed selection dial. The particular speeds which canbe used are controlled by the spindle speed rangecontrol lever. When the lever is set to the SLOWposition spindle speeds from 25 through 170 RPMare available. When the lever is in the FAST position speeds from 225 through 1500 RPM areavailable.COOLANT PUMP CONTROL

The coolant pump is driven through a manuallyoperated clutch either by the feed drive shaft or therapid traverse drive shaft. When driven by the feeddrive shaft coolant will flow only when the spindle isrunning. When driven by the rapid traverse drive shaftcoolant will flow when the drive motor is startedwhether or not the spindle is running. The clutch issecured in the engaged (down) or disengaged (up)position by a detent and can be shifted merely bymoving i t by hand.

The pump is normally driven by the feed driveshaft. To change the drive remove the pump coverplate and move the drive gear to the other side of thedriven gear. Rotate the cover plate end for end and replace it on the pump cover. Slip the drive clutch offthe feed drive shaft and catch the spring and two balls.Insert the balls and the spring in the hole near thebottom of the rapid traverse shaft and slip the clutch onthe end of the shaft to the disengaged (up) position.POWER FEE CONTROLS

These machines are equipped with levers for en

gaging power feed (when the spindle is running) toall movable units. When power feed is not desiredmove the control lever to the center or neutral po sition.A safety clutch in the feed gear train will slipautomatically to protect the gear train when an overload is imposed. f this happens reduce the feed rateand replace the cutter i f it has become dull. A safetyclutch in the rapid traverse drive will also slipautomatically if an overload is imposed while the rapidtraverse drive is operating. While these features havebeen incorporated to prevent expensive repairs andlost time it is still possible to break cutters bendarbors and damage gears. Develop the habit thereforeof seeing that the correct speed and feed is beingused that overhanging fixtures do not interfere withthe movement and that the cutter does not engage theworkpiece at the rapid traverse rate.Power movement of the knee is obtained by meansof the knee feed lever. The knee is fed downward bymoving the lever to the left.Power movement of the saddle is obtained by meansof the saddle feed lever. The saddle is fed to the rearor inward by moving the lever to the right.Power movement of the table is obtained by meansof the table feed lever. The table is fed to the right bymoving the lever to the right. The lever can be raisedto prevent interference with a pre-set table dog.

Power movement of the vertical sliding head isobtained by means of the vertical head feed lever.The head is fed downward by moving the lever downward.HAND FEE CONTROLS

These machines are also equipped with handwheelsand cranks for moving the various units by hand. Safetyinterlocks are incorporated in these controls to prevent their engagement while power feed is engaged andvice versa.Hand movement of the knee is obtained by meansof the knee hand crank. The knee is fed downward byturning the crank counterclockwise.Hand movement of the saddle is obtained by meansof the saddle handwheel. The saddle is fed to the rearor inward by rotating the handwheel clockwise.Hand movement of the table is obtained by meansof the table handwheel. The table is fed to the right byrotating the handwheel clockwise.Hand movement of the sliding vertical head isobtained by means of the head handwheel. The slidinghead is fed downward by rotating the handwheel clockwise. The spindle quill on swivel head vertical machines can be moved through a distance of 3-1/2inches by means of the quill handwheel. The quill isfed downward by rotating the handwheel clockwise.MICROMETER DIALS

Graduated micrometer dials on the handwheelspermit the movable units to be brought to any predetermined position. For example when the desiredposition of the table in a setup has been determined

BUILDERS OF PRECISION AND PRODUCTION MACHINE TOOLS FOR MILLING AND BORING4


16/27

Operator s Manual3hp No.1 Model CH - 3hp No.2 Model CHL - 5hp No.2 Model CH Plain - Universal- Vertical3hp IS 24 Model C Plain - Vertical Kearney Trecker - Milwaukee Milling Machines

the handwheel dial can be set to indicate this positionand the table can then always be quickly and accuratelylocated. The dials can be adjusted by pulling themoutward, rotating them to the desired setting and thenreleasing them.POWER FEED CHANGE CONTROL

The rate of feed movement for the knee, saddle,table and vertical head is indicated in inches per minute and is controlled by the feed selection lever andknob. To change the feed rate be sure the spindle isrunning. Withdraw the feed selection knob, rotate thelever in either direction until the arrow on the diallines up with the desired feed rate. Release the leverso that the plunger enters the hole provided and locksthe lever in position.

The feed rates and the range of feed rates for theknee and vertical head are one-half of those shown onthe dial. That is, i the arrow is lined up with 3/8,the saddle and table will feed at 3/8 inches per minute,but the knee and vertical sliding head will feed at3/16 inches per minute.RAPID TRAVERSE CONTROL

The knee, saddle, table and vertical sliding headcan be moved at the rapid traverse rate when themotor is running by first engaging the respectivefeed lever and then raising the rapid traverse lever.Refer to Section V page 18 for instructions on usingrapid traverse control in automatic cycle operation.

TRIP DOGS AND LIMIT STOPSAdjustable trip dogs are supplied to stop the travelof the movable units at any point within their range of

travel. The two dogs for the knee are located at theleft rear end of the knee. The two dogs for the saddleare located at the front and rear of the saddle to theleft of the way. Four dogs are used with the table andthe two dogs used with the vertical sliding head ar elocated on the right side of the head. Positive limitstops are also provided to restrict the total travel ofeach movable unit.

The four table dogs when properly used insure safeoperation and speed production. Figure 9 illustratesthe manner in which the dogs would be positioned fora typical setup. After the workpiece has been secured,the table is moved at the rapid traverse rate indicated by a full line) until the dog A) shifts the tabletrip lever to the neutral position and stops the table.This dog must be positioned to stop the table just beforethe cutter contacts the workpiece. This prevents anypossibility of the cutter engaging the workpiece whenthe table is moving at the rapid traverse rate and stillpermits the workpiece to be brought to the cutter inthe shortest possible time. Then, by raising the tablelever to bypass the dog and shifting it in the desireddirection, the table will feed dotted line). until thecutting operation is completed and the dog (B) shiftsthe lever to neutr?l stons the table. The table can

then be returned at the rapid traverse rate untildog C) stops the travel to complete the cycOperations in which a workpiece is loaded on eaend of the table can also be safely and quickly pformed by properly locating the trip dogs. We recomend that each setup be studied to determine that maimum use of the trip dogs is being made .CLAMPS

Clamps are provided to lock the movable unitsany position within their range of travel. The clalevers are serrated so that they can be removed areposi tioned i necessary. The knee is locked by movthe knee clamp lever outward. The saddle is lockby moving the saddle clamp lever inward. The tablelocked by moving the table clamp lever clockwiThe vertical sliding head (2CH models) is lockfor normal milling operations by pulling the heclamp lever forward, toward the operator. Fheavy duty milling, lock the head in pOSition wthe clamp lever and the three nuts, one of whichon the left and two of which are on the right sof the head. The spindle quill on swivel head vertimachines is locked by moving the quill clamp levclockwise and the swivel head is locked in plawith the four head locking bolts.

Be sure to clamp all units which will not be movduring the setup. For example, i a job requires otable travel, lock the knee, saddle and vertical heRelease all clamp levers when the job is finisheMICROMETER STOP RODS

The vertical machines can be equipped withsingle position stop or a four position turret stunit to limit the downward travel of the headsliding head vertical machines and the spindle quon swivel head vertical machines. The preCisistop screws are set by turning them in or outthe stop barrel and locking them in place with tlock nuts and the graduated collars. These collaare graduated in thousandths of an inch to permaccurate final setting of the screws.On machines equipped with four position turr

T B L E FEED TO LEF T

C A BI I .- F

ST1 RT ----------

Fig. 9 Use of Table Dogs

BUILDERS Of PRECISION AND PRODUCTION MACHINE TOOLS FOR MILLING AND BORING


17/27

Operator s ManualCH - 3hp No 2 Model CHl - 5hp No 2 Model CH Plain - Universal- Vertical

Model AC Plain - Vertical Kearney Trecker - Milwaukee Millin } Machinesstops, the dial indicator is used to accurately measurethe final depth of a cut. For example, i f a cut .005deep is to be made, the sliding head (2CH machines)can be power fed to trip out within approximately. 010 of the final setting with proper adjustmentof the stop rod. The final setting is then obtainedby hand -feeding the head while observing the dialindicator.

The four position turret stop, which can be rotatedby means of the precision stop ratchet lever, permitsup to four settings of the spindle for step millingoperations.SPEED AND FEED CHARTS

The following three charts are included at the rearof this manual:L Rules for determining speeds and feeds.2. Guide to correct speed selection.3. Guide to correct feed selection.

We recommend that these charts be used to determinethe proper speed and feed for the particular cutterand material being used.ARBOR SUPPORTS AND ARBORS

The arbor supports provide additional supportfor extended arbor and arbor assemblies. If the setuppermits the use of only one arbor support, additionalrigidity can be obtained by inverting the other supportand mounting it midway between the column and thesupport being used.When removing or applying arbor supports, extendone overarm approximately 6 inches beyond the other.Slide the arbor support first onto the extended overarm and then onto the other. Position the arbor supports and overarms, and then clamp them with thelock nuts. The adjustable arm feature permits arborsupports to be handled with a minimum of effort.

The spindle on 2CH machines is equipped with aNo. 50 standard non-sticking steel taper. The spindleson 1CH,2CHL and 18 -24 AC machines are equippedwith a No. 40 standard taper. The spindle is alsoequipped with two keys for driving arbors and cutters.When removing arbors, first loosen the nut on thearbor draw-in bolt at the rear of the column onhorizontal machines, and on top of the vertical headon vertical machines. Then hold the arbor and tapthe draw-in bolt with a soft hammer until the arboris loose. Screw the bolt out of the arbor and thenremove it. When installing an arbor, hold i t in placein the spindle taper, engage the draw-in bolt, thentighten the lock nut.Observe the following rules when working witharbors and arbor supports:

1. Tighten or loosen the arbor nut with the arborsupport in place.2. Be sure arbor nuts are always tight duringoperation.3. Adjust the arbor support bushings to providea running fit for arbor bearings.

4. Be sure the arbor diameter is large enough towithstand the cutting forces which will be encountered.5 Be sure the cutter-arbor setup runs true overits entire length.6. Be sure both spindle keys are seated properly .5 Keep the spindle, arbors and cutters clean. Evena particle of dirt can affect the accurate alignment ofthe preCision ground surfaces.8. When face mill cutters are mounted to thespindle, draw up the retaining screws evenly beforetightening them.9. Periodically check the oil level in the arborsupport oil sight gauge.OVERARMS

The arbor supports are mounted on two paralleloverarms which provide accurate alignment and maximum rigidity for the arbor and cutter assembly. Selfequalizing overarm clamps are locked and unlockedby means of clamp nuts.

The position of the overarms on 2CH machines canbe adj usted with the overarm handwheel. The left overarm only can be moved by pulling the handwheel outand rotating it in the direction desired. Both overarms can be moved simultaneously by pushing thehandwheel in and rotating i t in the direction desired.The right overarm can not be moved independently.The overarms on 1CH, 2CHLand 18 -24 AC machinesare moved by pushing them to the desired position.

The double overarms eliminate the necessity ofcompletely removing the arbor support when replaCingarbors and cutters. When this is necessary, merelyslide the support onto an extended overarm, swingthe support upward and let it rest on the other overarm.OUTER ARM BRACE

The outer arm brace is used to tie the overarmsand the knee together for heavy milling operations.The slots in the brace permit i t to be used at varioussettings of the knee. To install the brace, proceed asfollows:

1. Mount the arbor supports so that the outerface is flush with the end of the overarms.2. Position the overarms so that the arm bracecan be located as close to the saddle as possible.3. Mount the brace on the knee, bring it into contact with the arbor support and secure it to the arborsupport and knee.PULLEY BELT ADJUSTMENT

f the pulley belts become loose, adjust them -tsfollows:1. Loosen the lock nut on the adjustment screw atthe left rear of the motor base and the nut on the lockscrew at the right rear of the base.2. Lower the base using both screws until the

belts, at a point midway between the pulleys, can bedeflected sidewise by hand approximately 3/4 ineach direction from their normal position. Tightenthe lock nut on both screws to maintain the setting.



18/27

Operator s Manual3hp No.1 Model CH - 3hp No.2 Model CHL - 5hp No.2 Model CH Plajn - Universal- Vertical3hp IS 24 Model C Plain - Vertical Kearney Trecker - Milwaukee Milling Machines

SECTION V

UTOM TIC CYCLE OPER TION(18 _24 AC and 2CH Plain and Vertical Only

MONO-LEVER CONTROL OF T BLE Both feed and rapid traverse movements of(See figures 10 and 11) TABLE are obtained merely by changing the positof the mono-lever. In automatic cycle operatThis section describes operation of the 18 -24 the mono-lever is shifted by the rate, reverAC and 2CH plain and vertical machines equipped and stop dogs. In conventional operation the mon\vith the mono-lever for automatic cycle operation. lever is shifted by hand.

Fig. 10. Automatic Cycle Controls2CH Machines

I BOP DOG

Fig. 11. Automatic Cycle Controls - 18 - 24 AC Machines

BUILDERS OF PRWSION AND PRODUCTION MACHINE TOOLS FOR MILLING AND BORING


19/27

Operator s Manual3hp No.1 Model CH - 3hp No.2 Model CHL Shp No.2 Model CH Plain - Universal- Vertical

3hp 18 24 Model C Plain - Vertical Kearney &Treeker - Milwaukee Milling MachinesEach position of the mono-lever and the corre

sponding rate and direction of table travel is shownin Figure 12. The desired position of the mono-leverin automatic cycle operation is obtained by means ofthe dogs which are placed in the T-slots at the frontof the table. The three dogs used and their functionsare as follows:

1. A and B rate dogs - actuate the trip post andmove the mono-lever to either the feed or rapidtraverse position.2. Reverse dogs dep res s the reverse plungersand reverse the direction of table travel.3. Stop dogs - actuate the feed trip sleeve and movethe mono-lever to the neutral position to stop the table.

When using automatic cycle operation, be sure tofollow these instructions:1. Attach the dogs securely to the front of thetable. f the dogs are loose, they will move when

contacting the trip post and reverse plungers.2. Periodically grease the surfaces of the dogswhich contact the trip post and reverse plungers.3. Be sure that stop dogs are set ahead of andin contact with the reverse dogs. I f the dogs areset too far from the reverse dogs, they will move

the trip post and stop the table before the reversedogs can depress the reverse plungers.4. Be sure that the rate dogs are positioned sothat the bolted end is toward the trip post. Use theupper or lower table slot, whichever is required tomove the trip post in the proper direction.R TE SElECTOR KNOB

The rate at which the table travels after reversing in automatic cycle operation is controlled by therate selector knob. When the knob is set to readRAPID REV, the table will travel at the rapid traverserate after reversal. f the knob is set to read FEEDREV, the table will travel at the feed rate afterreversal.HANDWHEEl CONTROL OF T BLE

The table on automatic cycle machines can alsobe moved by means of the handwheel at the left end of

RATE CHANGEREVERSE P L U N G R ~ TRIP/OST REVERSE PLUNGER@c { b@

MONO-LEVER --......::--------1: : D-F EEO RIGHT

RT, OR.T. RIGHTNEUTRAL

Fig. 12. Mono-Lever Positions

the table. The handwheel automatically disengageswhen the mono-lever is used and can be re-engagedby setting the mono-lever to the neutral position andpushing the handwheel hub in to engage the clutch. fthe clutch does not engage easily, rotate the handwheel slightly while pushing the hub in.

Caution When moving the table by hand, besure that the dogs at the front ofthe table will not contact the reverse plungersor trip post.

KNEE SADDLE AND VERTICAL HEAD CONTROLOn 18 -24 AC machines, rapid traverse of the

knee and saddle is obtained by engaging the feedcontrol lever and then moving the mono-lever outward from the neutral positions (see Figure 12). On2CH machines rapid traverse of the knee, saddleand sliding head is obtained by engaging the feedcontrol lever and then raising the rapid traverselever on the right side of the knee.

Caution When rapid traverse mmement isused, be sure to engage the feedlever before engaging the rapid traverse

lever. f this is not done) the teeth on thereverse clutches may be damaged.

PLAIN CYCLE - RAPID TR VERSE RETURNIn all diagrams of automatic cycle arrangementswhich follow, the rapid traverse rate is indicated by

a full line and the feed rate is indicated by a dottedline. The rate dogs, both types A and B, are indicatedby circled let ters ,@, and in the diagrams. Theseletters are used only to identify the dogs in the il lustrations and are not to be confused with the typeof dog.Figure 13 illustrates the position of the dogs fortable travel which starts to the left. The workpieceis placed on the right end of the table and the cycleis started with the table at the right end of travel.With the selector knob (Figures 10 and 11) rotatedto read RAPID REV, move the mono-lever to the leftand then outward. The table will travel at the rapidtraverse rate until the feed dog @ contacts and de presses the trip post. This occurs just before thecutter contacts the workpiece. The mono-lever willthen shift inward to the feed position and the tablewill feed until the reverse dog depresses the rightreverse plunger to change the direction of table travel.The table will then return at the rapid traverse rateuntil the stop dog at the left end of the table movesthe trip plunger to the neutral position and stops thetable. A new workpiece is then put on the table andthe cycle is repeated.Figure 14 illustrates the position of the dogs fortable travel which starts to the right. The cycle operates the same as the one just explained except thatit is started with the table at the left end of traveland by moving the mono-lever to the right and thenoutward.



20/27

Operator s Manuallhp No. I Model CH - lhp No.2 Model CHl - 5hp No.2 Model CH Plain - Universal- Vertical3hp IS"- 24 Model AC Plain - Vertical Kearney & Trecker - Milwaukee Milling Machines

TABLE FEED TO LEFT

@I It

S T O ~ = D O G - - _ _ _ : : _ : : _ = _ L lob ~START FEED DOG STOP [) ) , REv. DOG

Fig. 13. Plain Cycle - Rapid Traverse Return Right to LeftTABLE FEED TO RIGHT

f0~ : ~ ~ ~ . - ~ ~ ~ : = - : j

.:,TOP DOG- __ - - - - -0 0REV. DOG 0 "STOP DOC; FEED DOG START

Fig. 14. Plain Cycle - Rapid Traverse Return Left to Right

TABLE FEED TO LEFT

~ -- r ~ . .= ~ ~ ~ ~ ~ - - T ~ ~ c ~ ~ j = F ~ ? = 4u _ REV.DOGFEED DOG STOP DOG

5TOP DOG

Fig. 15. Intermittent Cycle - Rapid Traverse Return Right to LeftTABLE FEED TO RIGHT

~ . - - 1 ~ ~ r - - - _ E = - ~ ~ ; ~ . = - ~ ~ - ~ - - . - ~ - ~C ~ : . - : : - - = k ; . . : ~ ~ . : : : : u __ ~ = ~ = u _ u ___ = - = - _ - - = l f = ~ - - 9

- f.REV. / .. STOP DOGDOG STOP DOG -F-EED DOG RT DOG .. rEED DOG-START

Fig. 16. Intermittent Cycle - Rapid Traverse Return Left to Right

Fig. 17. Continuous Cycle - Rapid TraverseINTERMITTENT CYCLE - RAPID TRAVERSE RETURN

Figure 15 shows the position of the dogs for tatravel which starts to the left. The workpieces aloaded and unloaded while the table is at the right eof travel. With the selector knob rotated to reRAPID REV, move the mono-lever to the left and thoutward. The table will travel at the rapid traverrate until the feed dog contacts and depressthe trip post. This occurs just before the cutcontacts the workpiece. The mono-lever will thshift inward to the feed position and the table wfeed to the left until the rapid traverse dog cotacts and raises the trip post. The mono-lever wthen shift outward and the table will travel atrapid traverse rate until the feed dog contaand depresses the trip post. This again occurs jbefore the cutter contacts the second workpieThe mono-lever will then shift inward and the tawill feed to the left until the reverse dog depressthe right reverse plunger to change the directiontable travel. The table will then return at the raptraverse rate until the stop dog at the left endthe table moves the trip plunger to the neutral psition and stops the table. Two new workpieces athen put on the table and the cycle is repeate

Figure 16 illustrates the position of the dogs ftable travel which starts to the right. The cyoperates the same as the one just explained excethat it is started with the table at the left endtravel and by moving the mono-lever to the rigand then forward.CONTINUOUS CYCLE - RAPID TRAVERSE

Figure 17 illustrates the position of the dogs fa two-station, high production setup. Since the cycis continuous, it can be started with the tableeither the left or right end of travel by moving tmono-lever to the feed position in the appropriadirection. In this cycle workpieces are unloadand loaded at one end of the table while the other worpiece is being milled.

Caution Since the table must reverse onlywhile it is in the feed rate and not

while in the rapid traverse rate, the dogs mustbe set so that the table is always in the feedrate at reversal.In this cycle the workpieces are conventiona

milled at one end and climb milled at the other. I timportant, therefore, that the backlash adjustmenoutiined in catalog CHI -11 be checked to insusatisfactory operation.

BUILDERS OF PRECISION AND PRODUCTION MACHINE TOOLS FOR MilLING AND BORING


21/27

Operator s Manual3hp No 1 Model CH - 3hp No 2 Model CHL - 5hp No.2 Model CH Plain - Universal Vertical3hp 18 24 Model C Ploin - Vertical Kearney Trecker - Milwaukee Milling Machines

OIL LEVEL GAUGJf7'\FILLER CAPOIL FLOW GAUGE

_ COLUMN DRAIN PLUGCD

OIL RECOMMENDED GARGOYLE D.T.E. HEAVY MEDIUM OR EQUIVALENT(SAYBOL T UNIVERSAL VISCOSITY 300-325 SECONDS AT 1000 FAHRENHEIT)

C)Z-..-0V-e:e0

::;e

C)Z0aZez

1

2

3

4

567S9p =

PARTS LUBRICATED R S R V ~CAPACIT INSTRUCTIONSSpindle DriveSpeed Gear Box 3 GallonsPulley Bracket Stop motor and add oil to maintainlevel ot upper line on sight gauge .Knee Drive Drain reservOir. Fill with flushingFeed Distribution Box solvent and mochine forpera tefeed and Rapid Traverse Drive 2'2 Gallons opproximately ten minutes, DrainBracket ond ref i l l reservoir,Column and Knee Ways

~ e v a t i n g ScrewSaddle and Table Drive Mechanism Withdraw and release pump handle.Knee and Saddle Ways 1 Pint Fill reservoir to VPPEH line on sightSaddle and Table Ways gougeArbor Supports Add oil to maintain le\lel at upperHne on sight gauge.Elevating Trip le\lerBracket BearingElevating Crank Bearing fill oil cups.Crossfeed Hondwheel BearingBracket Bearing

Spindle Bearings Use Socony.Vacuum SO\larex No.1grease or equivalent.

Fig. 18. Lubrication Chart-1CH, 2CHL 18 24AC Plain and Vertical Machines

fREQUENCY

As required.Every four months or each500 hours of machine oper-ation, whichever occurs first.

Six times per day,Daily.

Daily.

Daily.

Two s trokes with greoSegun every 200 hours ofoperation.

BUilDERS OF PRECISION AND PRODUCTION MACHINE TOOLS FOR MILLING AND BORING0


22/27

Operator s ManualJhp No.1 Model CH - Jhp No.2 Model CHL - Shp No.2 Model CH Plain - Universal- VerticalJhp IS - 24 Model AC Plain - Vertical Kearney & Trecker - Milwaukee Milling Machines

(

FILLER CAP U


23/27

Operator s Manual3hp No. I Model CH - 3hp No.2 Model CHL - Shp No.2 Model CH Plain - Universal - Verticol3hp 18 24 Model C Plain - Vertical Kearney Trecker - Milwaukee Machines

fiLLER GAP JIL LEVEL GAUGE -CDOIL fLOW GAUGEfLOW . LEVEL GAUGEl0DRAIN PLUG j \ : J

fiLLER GAP 3LEVEL GAUGE

11

KNEE DRAIN PLUG}


24/27

SAMPLE SPEED AND FEED CALCULATION .PROBLEM: Determine proper SPEED and FEED of a 5" diameter face

mill with 10 High Speed Steel blades, milling cast iron.A) TO DETERMINE SPEED DIAL SETTING (Cutter R.P.M.):

RULE: Divide the feet per minu\e (F.P.M.) by the circumference ofthe cutter. expressed in feet.FORMULA: F.P.M. Dia. 01 cutler x 11'12 R.P.M.

From Chart 2 under H.S. in50-80) is selected. Cast Iron, 80 F.P.M. (rangeTherefore: 80

3.14165 in. dia.15.7080

5 x 3.141612 R.P.M.

1.3112 )-f5)161.1 = R.P.M.

61.1 R.P.M.1.31 ) 8 0 ~ O O

SHORT FORMULA FOR SPEED:4 x F.P.M. R.P.M. or 4 x 805 -Diam. of Cutter 64 R.P.M.

B) TO DETERMINE FEED DIAL SETTING (Feed in inches per minute F):RULE: Multiply feed per tooth per revolution by number of teeth incutter and by the speed (number of revolutions per minute.)FORMULA: F.T.R. x T. x R.P.M. = F (Feed)

From Chart 3 under Face Mill H.S. in Caet Iron a F.T.R.(chip load) of .012 is selected (range .010-.025). R.P.M. ie61 from speed calculation.Therefore: .012 x 10 x 61 = Feed.732 Feed.

RESULT: For the 5" diameter face mill cutter with 10 High Speed blades,m.illing cast i ronThe SPEED dial setting is 61 R.P.M.The FEED dial setting is 7.32 I.P.M.

NOTE: The speeds and feeds determined by mathematical computation are approximate and dial sellings closest to theseresults (either higher or lower) are normally satisJactoryas a starting point.

TO FIND HAVING RULE FORMULASpeed ofCutter inFeet perMinute(F.P.M.)

Diameter of Cutter and Revolutions per MinuteDiameter of Cutter (In.)Multiplied by 3.1416,Multiplied by Revolutions per Minute, Divided by 12

D ~ , , - R , - , r . 1 . = F . P . M .- 12

RevolutionsperMinute(R.P.M.)Feet per Minuteand Diameterof Cutter

Feet per Minute, Divided by Circumferenceof Cutter in Feet (Diameter x 3.1416 ..; 12)F.P.M. ..;-Dx7r

12 R.P.M.

Feed perRevolution(F.R.)Feed per Minute Iand R e v o l u -tions per Minute Feed per Minute. Divided by Revolutions perlMinute F. R.P.M. F.R.

Feed per Feed per Minute (In.).Tooth per Feed per Minute Divided by Number ofRevolu and Number of Tee th p e r M i n u t e F ..;- (T. x R.P.M.)tion Teeth in Cutter (Number of Teeth in '" F.T.R.(F.T.R.) Cutter x Revolutionsper Minute)

Feed perMinute(F.)

Feed per Toothp_er Revolution,N u m b e r o fTeeth in Cutter, and Revol u t i o n s p e rMinute

Feed per Tooth per Revolution. Multiplied byNumber of Teeth inCutter, Multiplied byRevolutions per MinuteF.T.R.xT.xR.P.M. =F.

Feed perMinute(F.) tions and Revo-Feed per Revolu-I

l u t i o n s perMinuteMultiplied by Revolu-IFeed per Revolut iontions per Minute

F.R. x R.P.M. = F.Number of Number of Teeth I Number of Teeth in Cut-Teeth per in Cutter and ter Multiplied by Rev- T. x R.P.M. = T.M.Minute Revolutions per olutions per Minute(T.M.) Minute

R.P.M. = Revolutions per MinuteT. = Teeth in Cutter T.M. = Teeth per MinuteF. = Feed per MinuteD. = Diameter of Cutter.. = 3.1416 (Pi) F.R. = Feed per RevolutionF.T.R. = Feed per Tooth per Revolution

F.P.M. = Speed 01 Cutter in Feet per Minute

Fig, 21 Rules for Determining Speeds and Feeds

~....-....:

...~ ~2.::I1""Oa;1


26/27

Operator s Manuallhp No.1 Model CH - lhp No.2 Model CHL - 5hp No.2 Model CH Plain - Universal- Verticallhp 18"24"' Model C Plain - Vertical Kearney Trecker - Milwaukee Milling Machines

Feed per Tooth per Revolution-Chip Load[:'-'-:iI-....r----....

Face MillForm

Plain Slab

Staggered Tooth Spiral Two-LippedEnd Mill End Mill SawRecommended hip Load Tables

In BrassType of Cutter In Cast Iron In Steel BronzeAluminumFace Mill, H. S. .010 to .025 Less 40% Plus 50Slab Mill, H. S. .010 to .015 Less 40 Plus 50%Slotting Cutter, H. S. 006 to .012 Less 40% Plus 50%Form Mill, H. S. .004 to .006 Less 40% Plus 50End Mill, H. S. .002 to .010 Less 40% Plus 50%Saw, H. S. .001 to .003 Less 40% Plus 50%Cemented Carbide Face Mill .008 to .012 .004 to .008 .010 to .016In general, select the proper SPEED for work material and cutter; andthen determine the feed, within the above limits, according to the cut andthe power available or the finish required.

Fig 3 Guide to Correct Feed Selection

BUILDERS OF PRECISION AND PRODUCTION MACHINE TOOLS FOR MilliNG AND BORING


27/27

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were not scanned because they were blank.

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