-

-

Catalog No. CKI-12

-

-

20hp Nos. 2 and 3, 30hp Nos. 3 and 4

MODEL CSM

10hp No.2 and 15hp No.3 7V2hp No.3 andl0hp No.4

MODELCK MODEL CH

-

Plain- Universal- Vertical Milling Machines

-

t'v('r ond

with standard dir ectiono l table control

-

-

-

-

KEARNEY & TRECKER CORPORATION

MILWAUKEE 14, WISCONSIN, U. S. A.

-

FOREWORD

This manual contains instructions for installing the plam, universal and vertical styles of the following Kearney & Trecker - Milwaukee milling machines:

lOhp No.2 and 15hp No.3 Model CK 7-1/2hp NO.3 and 10hp NO.4 Model CH 20hp Nos. 2 and 3 Model CSM

30hp Nos. 3 and 4 Model CSM

This is an installation manual only. For operating instructions refer to the Operator's Manual, Catalog No. CKC-12.

Figures 6, 7 and 8 call out the main units of the machines. These units are indexed consecutively on the three illustrations and are referred to by means of index numbers throughout the manual.

All references to the machine, such as right and left, front and rear, etc. , are made from the operator's normal position while facing the machine.

It is our intention to continually improve the service you receive from Kearney & Trecker-Milwaukee milling machines and to make their operation as simple as possible. In accordance with this policy, we invite you to bring any questions and problems to the attention of the Service Department, Kearney 8.: Trecker Corporation, Milwaukee 14, Wisconsin, U. S. A . For service by telephone, call Greenfield 6-8300.

BUILDERS Of PRECISION AND PRODU<TION

MACHINE TOOLS FOR MilLING AND BORING

-

INSTRUCTIONS

FOR

INSTALLATION

-

-

UNCRATING

Remove the crating ami skids being careful not to damage or scratch the machine and its parts. If the machine or any contents of the crate are damaged, contact the transportation company which made the delivery.

SHORTAGES

-

Carefully inspect the contents of the parts boxes to see that all parts checked on the packing list are received in good condition. When more than one packing box is included in the shipment, the packing list will be found in the box marked "PACKING LIST INSIDE THIS BOX." Report shortages of parts checked on the packing list to the representative from whom the machine was purchased.

HOISTING

-

Caution Do not use a chain or cable for

hoisting. Use a 2 - inch manila standard spliced rope or its equivalent and protect the machine at all points of rope contact with wood blocks wrapped in burlap or wax paper. Be sure the machine is balanced

-

-

@

n

2CK }

3CH 7,500 lBS.

20hp CSM

3CK }

4CH 9,750 lBS

30hp CSM

Fig. I. Hoisting Horizontal Machines

in the rope sling before raising it to any great height.

To hoist horizontal machines (see Figure 1) place a wood block, which is tapered on the top edge to avoid cutting the rope, on the rear end of the overarms. Loop the rope under the rear end of the overarms, pass both strands through the crane hook and under the front end of the overarms and then loop the free end on the hook.

To hoist vertical machines (see Figure 2), loop the rope on the crane hook, pass both strands under the column, being sure to clear the levers and the sliding head, and then loop the free end on the hook. Insert a wood block between the rope and the column so that the rope clears the drive bracket.

LOCATION

The columns on these machines are finished on the bottom to insure level installation on a flat surface. Holes are provided in each corner to bolt the machine securely to the floor. If a concrete foundation is used, apply grouting to provide a solid base at all points. If the machine is installed on an upper floor, select a position, if possible, over a girder or at any point where the vibration is a minimum. Refer to Figure 12 for the plan drmenstons.

2CK }

3CH

20hp CSM

3CK }

4CH 10,400 LBS.

30hp CSM

Fig. 2. Hoisting Vertical Machine$

BUILDUS OF PRECISION AND PRODUCTION

1

MACHINE TOOLS fOR MILLING AND 110RING

10hp No.2 and IShp No.3 Model ac:

Installation Manual

7'hhp No.] and 10hp No.4 20hp Nos.2 and ], 30hp Nos.] and 4

Model CH Model (SM

CLEANING

Note Do not move any sliding unit until

all exposed surfaces are cleaned and oiled. Refer to the charts on pages 8 and 9 for lubrication instructions.

Remove the outer arm brace (14), both arbor supports (33) and (34) and release the overarm clamp nuts (35). Clean and oil the exposed surfaces of the overarms; then slide the arms forward and back by means of the handwheel (9) and clean and oil the center sections of the arms.

Remove all slush and grit from the entire machine with a suitable liquid cleaner. Release the table clamp lever (27), saddle clamp lever (23), knee clamp lever (22), and on the vertical machines the head clamp lever (54) and the three locking nuts (55). One locking nut is located above the clamp lever and two are on the opposite side of the head. Move each sliding unit by hand to the extreme limit in each direction and clean and oil the exposed surfaces.

LEVELING

Center the saddle on the knee and the table on the saddle.

Note If the table is crated separ at ely ,

refer to the assembly instructions given below under TABLE ASSEMBLY.

Insert a tapered wedge under each of the four corners of the column and adjust these wedges while taking lengthwise and crosswise readings with a precision level on the machine table. When the machine is level, insert additional wedges around the entire base and secure the machine solidly with lag screws or bolts.

T ABLE ASSEMBLY

The table, drive screw and component parts are occasionally crated separately to reduce the shipping space required. In such a case assemble the table and screw according to the following instructions:

1. Remove the wood block and table gib by releasmg and withdrawing both adjusting screws at the front dovetail ends of the saddle.

2. Clean and oil the saddle ways, dovetails and drive mechanism. Remove all parts from the ends of the table screw and clean and oil the entire screw. Insert the slotted end of the screw through the bronze keyed drive sleeve in the saddle and carefully thread the screw through the double bronze nut until it is centered on the saddle.

Caution To avoid damaging the screw

threads, check to see that the adjustable nut (See Figure 3.) in the saddle is in contact with the steel spacer and the fixed nut before inserting the screw. Secure the adjustable nut with the yoke provided or hold it in position while inserting the screw.

2

3. On CH machines only coat the contact face of the coolant return extension bracket with a suitable sealing compound and mount the bracket on the left rear end of the saddle with the three fillister head screws provided.

4. Check to see that the shoe of the table clamp lever (27) is in contact with the clamp screw and that the beveled end is flush with the tapered dovetails of the saddle. (see Figure 3)

5. Clean the table and insert a rectangular steel bar about one foot in length in the center T-bolt slot at each end.

6. Remove the coolant pocket block at the right rear end of the saddle.

7. Loop a rope sling around the extended ends of the steel bars, double the rope through a crane hook and move the table with the trip dog slot forward to the right side of the saddle. Raise the front end of the table slightly to clear the table feed control lever (26) and then slide the table to the center position on the saddle ways.

8. Clean, oil and sUde the table gib into the opening on the left side of the saddle and insert the gib screws.

9. Replace the coolant pocket block.

Note On machines equipped with automatic

cycle one of the table positive limit stops must be removed to provide clearance when assembling the table to the saddle. Be sure the limit stop is replaced immediately after assembly.

TABLE BRACKET ASSEMBLY • RIGHT HAND (SEE FIGURE 4)

1. Disassemble, clean and oil the bracket.

2. On the 3CK, 4CH and 30 hp CSM machines, carefully place the oil seal and carrier (A) on the shoulder of the table screw. On the 2CK, 3CH and 20 hp CSM machines, place the grease retainer (L) and bearing cover (M) shown in the inset on the table screw shoulder.

ADJUSTABLE

Fig. 3. Adjustable Nul and Cable Clamp

BUllOUS OF PRECISION AND PRODUCTION

MACHINE TOOLS FOR MilLING AND BORING

Installation Manual

-

-

3. Place the bearing (B) against the screw shoulder.

4. Mount the bracket (K) and install the bearing (C) with the slots in line with the keyway of the screw.

5. Tap the bearing cover (D) into position.

6. Install the clutch collar (E) so that the two tongues fit Into the recesses of the bearing and the pin fits into the keyway of the screw.

7. Install the lock washer (F) with the inner prong in the screw keyway. Thread the adjusting nut (G) onto the screw until the bearings (B and C) are seated firmly.

8. Coat the mating face of tbe bracket (K) with a sealer and, while holding the bracket upright, carefully move it with the screw into position and bolt it evenly to the table.

9. Tap the 011 seal carrier (A) into the bore on the inner side of the bracket.

10. lnstall the washer (1), nut (J) and the cover (H).

TABLE BRACKET ASSEMBLY • lEFT HANO (SEE FIGURE 5)

1. Remove the cover (R) and disassemble the yoke (U) and the spring (V).

Note Spring (V) is omitted on machines

equipped with automatic cycle table control.

2. Clean and oil the bracket (A), and the oil seal and needle bearing in the screw hole. Apply a sealer to the mating surface of the bracket and carefully place it in poSition on the screw. Tap the bracket lightly until it contacts the table and then secure it with the Screws.

~~~~:M-~~~~ I ..._.._ ........ ......_,

I 3CK, 4CH AND 30hp CSM

L...J'_~..J L . __ .,

,

2CK, 3CH AND 20hp CSM I

I

Fig. 4. Table Brocket Assembly - Right Hand

3. SHde the clutch plate (D) onto the screw (B) and align the rod (E) and the clutch plate so that they can be assembled to the screw with the pin and snap ring (C). Slide the rod in and out of the screw to be sure it moves freely.

4. Install the spring (V), the yoke (U), the pin (5) and assemble with the shaft (T) and the cover (R). Do not tighten the cover.

5. Slide the keyed shaft (W) through the gear in the saddle until the cam detent contacts the yoke nn.

6. Apply liquid sealer to the cover(R) and secure it to the bracket (A).

7. Set the Woodruff key in the screw (B). set the collar (0) in place and secure it with the screw (N). 8. Install the dial (M). the spring (F) and the retainer (G).

9. Fit the lever (Q) on the shaft (W) and secure it with the taper pin.

!2!! When the machine is not equipped with rear controls a eollar may rep1aee the lever.

10. Fit the handwheel (P) on the screw (B) and secure it with the pin and snap ring (L).

11. Insert the two elutches (8 and X), the knob (K) and secure them with the washer (1) and nut (1).

12 Fill the saddle reSerVOir with 011 to the Une oft the sight gauge (44) and operate the pump (43) several times to lubricate the table drive, the screw and the saddle ways.

HORIZONTAL CROSS-SECTION

Fig. 5. Tobie 8rocket As s e mb l y - Left Hand

SUllDERS Of PRlCISJOfl AND PRODU(TlON

IU(HINE TOOlS FOR MULING AND 80RING

3

-

Installation Manual

lQllp No.2 _ ISlip No.3 7%hp No.3 _ tOh, No.4 20hp NOJ.2 _. 3, JOhp Nos. 3; ond 4

......... ._ .. . __ M_.odt __ I_C_K. __ ._ ..• _ ___M_~!,,~ __ ~ M_odeI_·_· C_S_M __ ~ _

9

8 7

6 5

4

L Knee Oil Sight Gauge

2. Column Oil Sight Gauge

3. Speed Motor

4. Spindle Reverse Handle

5. Oil Filter

6. Table Handwheel

7. Speed Selection Knob

8. Speed SElection Lever

9. Overarm Handwheel

10. Column Oil Flow Gauge

11. Rear Table Feed Lever

12. Coolant Distributor Support

13. Coolant Distributor Nozzles

14. Outer Arm Brace

15. Saddle Oil Sight

Gauge

16. Bijur Pump

17. Saddle Feed Lever

18. Knee Feed Lever

19. Saddle Handwheel

20. Knee Hand Crank

21. Feed Selection Knob

22. Knee Clamp Lever

23. Saddle Clamp Lever

fig.6. Plain Machine - Left Front View

4

BUILDERS Of PRECISION AND PRODUCTION

MACHINE TOOLS fOR MILLING AND BOltiNG

-

... ---.-"--,-.- .. --.-----, ... - .. -~

-

-

25

30

27--

26

-

-

24. Telescopic Coolant Return Tube

25. Rapid Traverse Lever

26. Table Feed Control Lever

27. Table Clamp Lever

28. Left-Hand Table Trip Dogs

29. Right-Hand Table Trip Dogs

30. Arbor Support Oil

Sight Gauge

31. Starting Lever

32. Arbor Support Lock Nut

33. Style "B" Arbor Support

34. Style' 'B" Intermediate Arbor Support

35. Overarm Clamp Nut

36. Coolant Distributor Parking Stud

37. Arbor Draw-in Bolt

38. Master Start and Stop Buttons

39. Coolant Pump Switch

40. Pulley Drive Bracket

41. Electrical Control Panel

42. Feed Motor

43. Coolant Pump Motor

44. Coolant Pump

Fig. 7. Plain Machine - Right Front View

BUILDERS OF PRECISION AND PRODUCTION

MACHINE TOOLS fOR MILUNG AND BORING

5

-

Installation Manual

IOhp No.2 and 1Shp No.3 71hhp No.3'" 1011p No.4 10ilp Nos.2 and 3, 30bp NOi.3 OM 4

Model C1( lWeI at Model CSM

52

54 55 56

51

50 49 48

41

45. Coolant Distributor Support Rod

46. Vertical Head Trip Dogs

47. Vertical Head Handwheel

48. Dial Indicator

49. Graduated Collar

50. Nut

51. Precision Stop Screw

52. Column Oil Flow Gauge

53. Arbor Draw-in Bolt

54. Vertical Head Clamp Lever

55. Vertical Head Lock Nut

56. Starting Lever

57. Vertical Head Oil Sight Gauge

58. Precision Stop Ratchet Lever

59. Vertical Head Feed Lever

60. Coolant Distributor Nozzle

61. Coolant Distributor Parking Stud

62. Coolant Distributor Clamp

fig. B. Vertical Head - Left and Right Front Views

6

BUILDERS OF PRECISION AND PRODUCTION

MACHINE TOOLS fOR MILLING ANI> 80RING

-

Installation Manual

Milling Machines - Plain, Universal and Vertical

-

13. Adjust the table gib as follows:

-

a. Loosen the screw at the small end of the gtb 1/4 turn and tighten the screw at the opposite end the same amount.

b. Repeat this operation until a slight drag is felt when moving the table by hand the full length of travel in both directions.

c. Tighten both screws slightly to maintain the adjustment.

14. Adjust the thrust bearing and backlash eliminator as follows:

-

a. Remove the cover (H, figure 4) on the right end of the table.

b. Screw a 6-inch stud into one of the screw holes in the bracket and attach a dial indicator to the stud so that the indicator button contacts the end of the table screw.

c. Move the table in both directions and note the mean lash reading on the indicator dial.

d. Disengage the prong of the lock washer (F) and turn the adjusting nut (G) clockwise until the lash shown on the indicator dial when the screw is rotated is not more than .001 inch.

e. Engage the prong of the lock washer (F) and replace the cover (H).

f. Release the two nuts (A, figure 9) on the backlash eliminator. Thts assembly is located at the left end of the saddle.

g. Release the front adjusting screw (B) several turns and take up the rear screw (C) so that the yoke (0) rotates in the direction of the arrow.

h. Take up the screw (C) until a binding between the table screw and nut is felt when the table handwheel (P, figure 5) is rotated. (Hand movement of the table on machines equipped for automatic cycle operation is accomplished by pushing the handwheel clutch hub (K) in to engage the handwheel.) When this binding is felt, release the screw (B, figure 9) to secure the yoke (D). Repeat this procedure only until the table can be freely moved with the handwheel to complete the adjustment. Be sure to secure the screws (B and C) with the nuts (A) when the proper adjustment has been made.

i. If the yoke can not be rotated sufficiently to eliminate the excess lash, remove it from the adjustable nut, rotate it a few serrations counterclockwise and replace it on the nut.

Fig. 9. Left End View of Saddle

ELECTRICAL CONNECTIONS

For correct line lead connections, refer to the instructions secured to the tnstde of the electrical control cabinet door and on the cover of the line terminal block. Remove V -belts before checking pulley rotation, then proceed as follows:

1. Check to see that the oil level in all the sigh gauges (1, 2, 15 and 57) is at the required level.

2. Start the spindle drive motor by moving the starting lever (31) to the left; on vertical machines move the lever (56) upward. Observe the direction of rotation of the motor pulley.

~ Do not install the belts on the pulley

until the direction of rotation has been checked.

3. If the rotation is as indicated by the arrow on the pulley, install the belts. If the direction of rotation is opposite to the arrow, shut off the power and reverse the line leads (LI and L3).

FOR OPERATING INSTRUCTIONS REFER TO OPERATOR'S MANUAL, CATALOG NO. CKC-12

FOR REPLACEMENT PARTS MANUALS AND MAINTENANCE INSTRUCTIONS REFER TO THE FOLLOWING MANUALS:

Catalog CRR-30 for Nos. 2 and 3 CR machines Catalog CRR-35 for Nos. 3 and 4 CH machines

Catalog SMR-20 for 20hp Nos. 2 and 3, and 30hp Nos. 3 and 4 CSM machines

BUILDERS OF PRECISION AND PRODUCTION

MACHINE TOOLS FOR MILLING AND BORING

7

-

10h, No.2 ClIId IShp No.3 Model (J(

Installation Manual

11f2hp No.3 alld 10hp No.4 20hp Nos.2 alld 3, 30t!, Nos.3 and 4

Model 01 Model CSM

...------OIL FILTER ....... ---F'ILLER CAP .----ORAIN PLUG

OIL LEVEL GAUGE Oil FLOW GAUGE

ORAIN PLUG tiLLER CAP LEVEL GAUGE

OIL RECOMMENDED: GARGOYLE D. T. E. HEAVY MEDIUM OR EQUIVALENT (SAYBOL T UNIVERSAL VISCOSITY 300-325 SECONDS AT 100· FAHRENHEIT)

RESERVOIR CAPACITY
lOCA· .2CK·3CH 3CK·4CH FREQUENCY
TION PARTS LUBRICATED .20hp CSM 30hp CSM INSTRUCTIONS
e
Z Spindle Drive Stop motor and add oil 10 maintain
- 1 Spud Gear Box 2 Gallo"5 3 Gallons A. required.
_. Pulley Bracket level at upper line on 51ghl gouge.
-
0 Knee Drive D,oin r.servoir. flush with kerosine Every four months or each
'" feed Distribution Box liquid Hllshing solvent for ten 500 hour, of machine oper-
feed and Rapid Traverse Drive 1% or ati on, wh kheve r O«U'S first.
- .2 .2 Gallons
... Bracket Gallant minutes with motor running_ Refill
C Column and Knee Ways
2: Elevating Screw reservoir.
0
... Saddle and Table Drive Mechanism Wilhdrowand release pump handl e. Six times per day.
:I 3 Knee and Saddle Ways 1 Pint 1 Pint
C Saddle and Table Way. fill reservoir. Daily.
.. Arbor Support • Add oil to maintain level at upper Daily.
line on 'ight gauge.
e 5 Table Hondwheel Beatings
Z Bracket Bearings
- 6
_. Hondwheel Release Shoft
- Daily.
0 7 Elevating Crank Bearings Fill oil cup s,
A 8 Crouf.ed Handwhe.1 Bearings
Z 9 Bracket Bearings
C
:r: 10 Coola nt Pum p Fig. 10. Lubrication Chart-Horizontal Machines

8

BUILDERS OF PRHISION AND PRODUCTION

MACHIN! TOOLS FOR MillING ANI> BORING

-

-

-

-

-

Installation Manual

Milling Machin'$ - Plain, Universal and V.rtical

---------------------------------------------------------------------_/

.-------OIL F'II..TER .----- fILLER CAP DRAIN PLUG

DRAIN PLUG- fILLER CAP FLOW & LEVEL GAUGE

PUMP----./ fiLLER PLUG DRAIN PLUG

OIL RECOMMENDED: GARGOYLE D.T. E. HEAVY MEDIUM OR EQUIVALENT (SAYBOL T UNIVERSAL VISCOSITY 300-325 SECONDS AT 100· FAHRENHEIT)

RESERVOIR CAPACITY
lOCA- 2CK-3CH 3CK-4CH INSTRUCTIONS FREQUENCY
TION PARTS LUBRICATED 20hp CSM 30hp CSM
e
Z Spindle Drive Slop motor and add oi! 10 maintain
- 1 Speed Gear Box 2G"lIon. 3 Gallons As required.
... Pulley Bracket level 01 upper line on sight gauge.
-
0 2 Vertical Head Dri .. and Ways % Quart 1 Quart
u Knee Drive Drain reservoir. Flush with kerosine Every four months or each
- feed Distribution Box 500 hours of machine oper-
.. liquid flushing so Ive nl for Ie n
C Feed and Rapid Travers e Drive I~ or alion, whichever occurs first.
~ 3 Bracket Gallons 2 GaHons minutes with motor running. Refill
0 Column and Knee Ways reservoir •
.. Elevating Screw
:;,
C Saddle and Table Drive Mechanism Withdraw and relecse pump handle. Six limes per day.
4 Knee and Saddle Ways I Pint I Pint
Saddle and Table Ways Fill relervoir. Daily.
5 Tobie Handwheel Bearing.
6 Bracket Bearings
e Handwheel Release Shalt
Z 7 Elevating Crank Bearings
-
.. eronfoed Handwheel
- 8 Bearing$
0
9 Four Position Stop Fill oil cups. Daily.
e 10 Head Handwheel Bearings
Z
<l II Handwheel Shaft Bearing
% Bracket Bearing$
12
13 Coolant Pump Fig. 11. lubrication Chart-Vertical Machines

BUllOUS Of PRECISION ANO PRODUCTION

9

MACHINE TOOLS fOR MIlLING AND BORING

Installation Manual

e 10hp N4,2 ond ISlip No.3 7'/1hp No, 3 lind 10hp N4.4 20hp Nos.2 and·3, lOhp Nos.3 and 4

~ ~M~"~e~I~C~K =M=~~m= ~ ~~== .. ~a~M= . __

'I l

t(~'''''',--...

~

A

No leI( 20h" No. Z CSM 46';l 51R

No. 3CH - 2011" No.3 eSM 46'11 51 R

No. 3el( ._. 30t." No.3 CSM 57';

No 4CH - 30h" No.4 CSM snz

55 55 6tH 61!'1

e

26~'e 26y' 31t(. 3n{~

o o o o

17 17 18 18

28F 2SF

29jiR 24f 29hR ?<IF az

32

2S.1/,R 2,SI/tR 28

28

o

2 '2 'l 2

E'

F Min. F Ma., F Mo., G Plain Univ.

Ii

'l 2 2 2

p p

Plain Urtlv.

56 64 64 74

M Univ

N

78'1 50"8 49'8 56); 86', 58', 55.'~ 62~z 90's 61'-;; 56'~ 63~~ 105!~ 76'1 64~';; 71h

.oil'" 62'1 491 62'1 48'" 66"~ 58; 661~

48 48 50 50

20 20 2S!, 1S!,\

AA

ee

DO

EE

fF

GO

ss

4 .4 5

4~'3

NOTE"On machine, ""ilh Mano·l~v('r roblc control· ;"1" 125.4mmt I" .. : '2" (5Imm) len; ',3" (76mm) 1'>$>.

Hii

Kle II Min. llMo~,

1334 6~ 13!1, 6X 15>i 8~. 1Sh sH

A

M

4~!;l 51 R 46',l SIR 57!, 57',

No 1Ck 20h" No 2 CSM

N(, 3CH 20h" No.3 C5M

No lCK 30hp No 3 CSM

No KH _ .. 30n" No 4 CSM

55 55 61',

61 '"

c

e

o o o o

1'1

2ap 29"sR

28f 29l.~R 32

32

Ie

24f 251tSR

2.4f 25!i,R 28

28

71jr, 79~'8 82~~ 971"

'2 2 '2 '2

F Min. f Max. G

'~{. 'Y,. 11/ '16

IJ/

,.

'2 2 2 2

N

P

Q

s

7's?8 75% 81~ 61-!1

56 64 64 74

T Min. T Mo x .

46 46 48~~ 48%

v

DO

ee

FF

GG

1'11'1

NOTE ·0" _chine, with Mono,lever roble cenrrol. "I" l25.4mml Ie •• ; <2" (51mm} I" •• ; P" (76mm) Ie ss., fig. 12. Pion Dimension.

10

8UILOER) OF PUCISION AND PRODUCTION

JJ

KK

II Min. llMa.,

MACHINE TOOlS FOR MIlliNG AND BOltiNG