SHAPING MACHINE EXCEL model XL 632 UN-PACKING The machine is packed either in a special timber crate or, covered

with Polyethylene mounted on a timber pallet. Asphalt paper is inserted between the frames and the timber of the walls and the lid of the crate. The machine is un-packed taking down firstly the lid and then the sidewalls. After un-packing, inspect the machine carefully. In the event of shortages or damaged parts, notify the supplier immediately giving a clear indication as to which parts are damaged/missing. The accessories of the machine are packed in separate small boxes inside the crate. LIFTING AND MOVING Handling the machine after un-packing must be done by a lifting device of adequate capacity i.e. in excess of 2200 Kgs for safety reasons- Ensure the correct method of carrying the machine is in accordance with the equipment's construction and geographical features of the Plant. The machine should be lifted at the points indicated on the packing - see below

CLEANING Prior to installation, the machine must be cleaned thoroughly of the protective grease. Initially, the protective layer is removed mechanically with a wooden spatula and then washed with diesel fuel oil. The surfaces should then be wiped with a soft cloth. DO NOT USE METALLIC SPATULAS OR SCRAPERS WHICH MAY DAMAGE THE MACHINE'S SURFACES AND PAINT.

FOUNDATION The machine must be installed on foundations suitable for reliable and accurate running. For best results, it is important that the machine Is positioned on a solid and firm cement foundation. Away from heavy vibrations. The machine should be located so that adequate space is provided and the following points should be taken into consideration:The maximum travel of the ram is 650mm i.e. 20mm longer than the maximum machining length. The screw head of the cutting tool post at the front terminal position protrudes 200mm ahead of the front end of the table. See illustration below. If gripping is at the front end of the channel, the ram protrudes 290mm behind the guard in its rear terminal position. Locations of the ram are indicated below:

FOUNDATION The recommended dimensions for the base area are shown in the foundation plans To guarantee precise operation of the machine, it should be located over strong foundation plates and filled with concrete of a grade not less than 150. Securing the machine to the foundation plates is via 6 No- adjustable bolts as shown in foundation plans In the threaded holes of the base area, there are hollow bolts (5) and their positions in height are secured via lock nuts (6). By means of these bolts, the machine steps over the steel piates 1, 2 and 3 which lie over the foundation plates. The hollow bolts (5) serve for leveling and bolts (7) secure the machine, to the foundation plate. The base area should be filled with concrete leaving 6 holes for the foundation bolts (7). These bolts are placed in the holes and are covered with pure cement/mortar - the distance between them is kept within an accuracy of 1mm. After allowing the cement to cure, the machine should be placed over the foundation area. To level the machine, the table should be set in its mid position and the upper working surface of the table at a distance of 220mm from the sideways of the ram. The center channel should coincide with the ram axis. The four hollow bolts do leveling the machine in the longitudinal and transverse plane by means of which the machine lies over the steel plates 2 and 3 and are controlled with a level placed over the upper working surface of the table. The accuracy of the leveling is 0.04/1000mm/mm To set up guide 'H' of the base to a parallelism in relation to the upper working surface of the table, is done by the two hollow bolts. As one end of the guide is being raised, the other end is being lowered until it has established itself, ft is controlled with a level which is placed over the table and after, over the center of the guide - it should show one accurate reading. Upon completion of leveling, the hollow bolt locking nuts should be tightened and the area between the machine base and the concrete plate should be filled with pure cement mortar. Allow the cement to cure before finally securing the nuts of the four foundation bolts.

SAFETY PROCEDURES Safety is a combination of operator common sense and alertness at all times when the machine is being used. Study these general safety rules before operating the machine. 1. Never operate the machine without wearing the correct protective clothing i.e. * Safety Shoes * Safety Glasses * Overalls - DO NOT WEAR LOOSE CLOTHING * DO NOT WEAR JEWELLERY i.e. RINGS WATCHES ETC. 2. Make sure the machine is suitably positioned and that the surrounding floor area is kept dean and free from scrap metal, oil and grease. 3. Always replace warning labels if they become obscure. 4. Always concentrate on your work - careless acts can result in serious injury. 5.Personnel not connected with the machine's operation should be kept at a safe distance from the work area. 6. ISOLATE POWER IN ADVANCE FOR MAINTENANCE AND REPAIRS. 7. Maintenance, inspection and repair must only be undertaken by qualified personnel. WARNING: FAILURE TO COMPLY WITH THE ABOVE CAN RESULT IN SERIOUS INJURY

PRINCIPLE OF OPERATION The eccentric is orientated angularly in relation to the shaft of the connecting link wheel in such a way that in backward travel of the connecting link, the eccentric starts to push the conductor 13 to the left. The movement of the worm rack -o results in the screw of the table turning through the safety coupling and the ratchet wheel gear. In turn, the worm rack to the right of the ratchet wheel mechanism acts no more and consequently the table returns back. In regulating the magnitude of the feeding by screwing in the nut, the right position of the set-in worm rack will travel the roller and come into contact with the eccentric. Feeding movement of the table is different but it will always end when the connecting link arrives in its back terminal position. When changing the vertical position of the machine table, the distance between the axis of the connecting link shaft and the axis of the primary (drive) shaft of the distribution box changes. The compensation of this change of distance is accomplished by changing the working length of the worm rack where it occupies a different slope in relation to its horizontal position. The housing 14 may revolve around the shaft of the connecting link wheel and the sleeve 3 - around the primary (drive) shaft of the distribution box. CONNECTING THE MACHINE TO THE MAINS SUPPLY Before connecting the machine to the mains supply, the following instructions should be noted: -: 1. Inspect the electrical panel and ascertain whether the frequency and voltage correspond to those of the electric set. 2. Select a feeder cable with a cross section corresponding to the set. 3. Ensure the feeder cable is connected to the earth wire and terminals R, S and T with the bolt for earthling. CONNECTING THE MACHINE TO THE FEEDER LINE The earthling of the machine and the electrical installation is carried out in accordance with the requirements of the relevant regulations The feeding cable should be with a cross section of 3 x 1.5mm2 +1x1.5mm2 well insulated and placed in a steel armour or suitably enclosed in an area close to the machine. Inspect and clean out all dust and dirt from contacting surfaces of the electrical apparatus. Upon completion of the above requirements, the ends of the three phases of the feeding cables are connected to the terminals and the earthling conductor is connected to the earthling screw on the entrance box. The directions of the rotation of the electric motor should then be inspected.

ELECTRICAL INSTALLATION The electrical installation of the machine consists of: - Main electrical motor - Electric motor for fast displacements of the table. - Electrical panel - Electrical control members and connection cables * The electrical motors are 3 phased asynchronous having short circuited rotor-

The entire electrical equipment is enclosed in a cabinet attached to the machine. The electrical installation is normally equipped for a voltage of 380v and a frequency of 50 Hz. A lamp for local illumination can be connected in the plug box. See electrical schematic diagrams MC200010-01 - MC200010-03 OPERATION The main electric motor M1 is switched on by pressing the press button SB1 situated on the control panel. Self-blocking of the contactor K1 through its opened contact K1 follows:For fast displacement of the table, the electric motor is switched on through button SB2. The electric motor runs as long as the button is pressed on. Electrical switches E1/E2/E3 are situated at the terminal positions of the horizontal and vertical displacements of the table. Switch El limits the table travel at the terminal left hand position. Switch E3 limits the table travel at the terminal upper position. At the actuation of these switches, the main electric motor and the electric motor for the fast displacement of the table are switched off. By pressing button SB-0 un-conditionally stops the electric motors Ml and M2. The automatic switches SA1, SA2, SA3, SA4, SA5 and SA6 ensure protection against over-loading and short circuits of the electric motors and transformer. PROTECTION The main electric motor M1 is protected by a maxim-1 electric current protection and a thermal protection built-in in the inlet- automatic safety type SA1, AT-00.

SERVICE AND MAINTENANCE Servicing and repairs of the electrical installation should be undertaken only after disconnecting the machine from the feeder line by means of the main switch and isolating the power supply. A qualified person should inspect all electrical components at regular intervals. The electric motors should be cleaned of dust, oil and other contamination at regular intervals. A periodic check and cleaning with a file of the contact surfaces of the electrical apparatuses should also be carried out. The machine should be tested through all motions before operation. OPERATING THE MACHINE The machine is connected to the feeder line by means of the main starter - lamp 22 will light up- the main electric motor is switched on by pressing the start button 20. The machine should be left running for 5 minutes to enable lubrication of all the mechanisms- Fast travel of the table is switched on by pressing button 21. Switching on and regulating the working members is as described in Section "Control and Setting Up" NOTE: To ensure a long lasting, reliable and accurate performance from this machine, the following must be observed:* At the start of each shift, lubricate the sideways of the ram and the connecting link mechanism without starting the ram in motion as detailed in Section "Lubrication" * The oil level in the reservoirs of the central lubrication system and speed box, should be above the minimum shown. * Oil should always be flowing in the gauge window of the central lubrication system. * The main electric motor should not be switched on with the clutch of the speed box being engaged. Before switching on the vertical automatic feed and fast travel of the table, check that the front support of the table and saddle are adequately loose. * Before switching on the automatic feeding of the cutting tool post, check that its slide is adequately loose. * After re-setting the ram, it should be secured firmly by means of lever 18.

* Firm tightness of the front support of the table and saddle when feeding horizontally, guarantees precise operation of the machine.

* Ensure that the cutting tool or slide will not strike the body of the machine when rotating the cutting tool head. * To observe the limiting values of the double stroke is dependant on the length of the ram travel.