Hercules 2005: Operator Manual

OPERATOR MANUAL
HERCULES 2005
CLEVELAND BRIDGE
PART No 594953
Cleveland Bridge & Engineering
2005 Hercules
Table of Contents
0. SAFETY ISSUES ................................................................................................................ 5

0.1 MACHINE SAFETY .............................................................................................................................. 5
0.2 PLASMA ARC RADIATION................................................................................................................. 5
0.2.1 Eye Safety ........................................................................................................................................ 6
0.2.2 Skin Safety ....................................................................................................................................... 6
0.3 TOXIC FUME PROTECTION ............................................................................................................... 6
0.3.1 Noise................................................................................................................................................ 8
0.4 FIRE PREVENTION ............................................................................................................................ 10
0.5 ELECTRIC SHOCK PREVENTION.................................................................................................... 10
0.6 GROUNDING....................................................................................................................................... 11
0.7 EXPLOSION PREVENTION............................................................................................................... 11
0.7.1 Pressure Regulators ...................................................................................................................... 12
0.7.2 Compressed Gas Cylinders ........................................................................................................... 12
0.7.3 Hoses ............................................................................................................................................. 12
0.8 SAFETY REMINDERS ........................................................................................................................ 13
0.8.1 Precautions Summary.................................................................................................................... 13
1. GENERAL NOTES........................................................................................................... 14
1.1 SAFETY................................................................................................................................................ 14
2. DAILY CLEANING AND CHECKING .......................................................................... 14
2.1 GENERAL ............................................................................................................................................ 14
2.1.1 Rail axis racks ............................................................................................................................... 14
2.1.2 Beam axis rack (Item s19) ............................................................................................................. 14
2.1.3 Beam axis linear rails.................................................................................................................... 15
2.1.4 Swarf.............................................................................................................................................. 15
2.1.5 Rail wipers, drive side (Item s30), Slave side (Item s23).............................................................. 15
3. WEEKLY CLEANING AND LUBRICATION ............................................................... 16
3.1 BEAM AXIS LINEAR BEARINGS (ITEM S24) ................................................................................ 16
3.2 RAIL AXIS RACKS, BEAM AXIS RACK ......................................................................................... 16
4. MONTHLY SERVICE...................................................................................................... 16
4.1 SUPPORT WHEEL BEARINGS, DRIVE SIDE (ITEM S1), SLAVE SIDE (ITEM S22) .................. 16
4.2 RAIL GUIDE ROLLERS...................................................................................................................... 16
4.3 RAIL AXIS DRIVE GEAR BOXES/BEAM AXIS DRIVE GEAR BOX ........................................... 19
4.4 LUBRICATION POINTS WITHIN THE DRILL BOX....................................................................... 22
4.5 TORCH LIFTER LINEAR RAILS AND BEARINGS......................................................................... 22
4.6 TOOL CHANGER LUBRICATION .................................................................................................... 24
4.7 BEAM AXIS CATERPILLARS (ITEMS S9, S17), CATERPILLAR TRAYS (ITEM S18)............... 24
4.8 CABINET AIR CONDITIONER (ITEM S5) ....................................................................................... 24
4.9 POWER CABINET FAN UNIT AND AIR OUTLET FILTER - (RITTAL 3165, 3160) ................... 24
4.10 LOCK OUT STOP SWITCHES ........................................................................................................... 24
5. THREE MONTHLY SERVICE....................................................................................... 25
5.1 CONTROL CABINET (ITEM S4), CONTROL PANEL (ITEM S3) ................................................ 25
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5.2 CATERPILLARS, CABLES AND HOSES FOR BOTH AXES (ITEMS S8, S9, S17) ...................... 25
5.3 FEED HOLD AND EMERGENCY STOP LIMIT SWITCHES (DESCRIPTION AND TESTING) 25
5.3.1 Feed hold limit switches ................................................................................................................ 26
5.3.2 Emergency stop limit switches....................................................................................................... 27
5.4 CRASH PROTECTION LIMIT SWITCHES (DESCRIPTION AND TESTING) .............................. 27
5.4.1 Rail axis......................................................................................................................................... 27
5.5 FOOT PROTECTION........................................................................................................................... 28
5.6 TORCH PROTECTION........................................................................................................................ 28
5.7 MAGNETIC BREAK AWAY JOINT(S) ............................................................................................. 28
5.8 TORCH BOXES (ITEMS S15, S16) .................................................................................................... 28
5.8.1 General.......................................................................................................................................... 28
5.8.2 Lifter bands (Fig. 10, Item 19) ...................................................................................................... 30
5.8.3 Top limit switches (e.g. Fig. 10, Item 16) ...................................................................................... 30
5.8.4 Band break limit switches (Fig. 10, Items 15 and 16) ................................................................... 30
5.9 AXIS DRIVE MOTORS (E.G. ITEMS S13, S27) , SPINDLE DRIVE MOTOR (ITEM S25) ........... 30
5.10 CABINET AIR CONDITIONER (ITEM S5) ....................................................................................... 30
6. ADJUSTMENTS ............................................................................................................... 30
6.1 RAIL GUIDE ROLLERS, DRIVE SIDE (ITEM S29), SEE ALSO FIG. 2. ........................................ 30
6.1.1 Description .................................................................................................................................... 30
6.1.2 Adjustment procedure.................................................................................................................... 31
6.2 AXIS DRIVES ...................................................................................................................................... 32
6.3 AXIS DRIVES (EG. ITEM S26), REFER FIG. 12............................................................................... 32
6.3.1 Beam axis drive (Item s12) ............................................................................................................ 35
6.3.2 Rail axis Slave drive - Description ................................................................................................ 37
6.3.3 Adjustments ................................................................................................................................... 37
7. RECOMMENDED GREASE............................................................................................ 38
8. SPARE PARTS (RECOMMENDED TO BE HELD IN STOCK) ................................... 38
9. ITEM NUMBER IDENTIFICATION............................................................................... 39
List of Figures
Figure 1 Wiper Assembly........................................................................................................ 15
Figure 2 – Support assembly, drive side .................................................................................. 17
Figure 3 – Support assy. slave side .......................................................................................... 18
Figure 4 – Guide rollers slave side ........................................................................................... 19
Figure 5 – Inspection window, gear box .................................................................................. 20
Figure 6 – Drillbox lubrication................................................................................................. 21
Figure 7 – Toolchanger linear rails and bearings ..................................................................... 23
Figure 8 – Rail limit switches................................................................................................... 26
Figure 9 – Beam limit switches ................................................................................................ 27
Figure 10 – Lifter assembly (typical) ....................................................................................... 29
Figure 11 – Support wheel assy................................................................................................ 31
Figure 12 – Drive gear box, cross section ................................................................................ 32
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Figure 13 – Plunger assembly. rail axis gear box..................................................................... 34

Figure 14 – Gearbox, top view ................................................................................................. 36
Figure 15 – Slave assembly (detail) ......................................................................................... 37
Figure 16 - - Isometric View of a Typical HERCULES with Item Numbers .......................... 39
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0. SAFETY ISSUES
0.1 MACHINE SAFETY
Warn other people in the area of potential dangers as listed in this manual.
Stop the machine if anyone's personal safety is at risk.
When the machine is to be left unsupervised actuate the feedhold or emergency

stop.
Never stand on the machine rails.
Never work on or near the machine when it is operating.
Care must be exercised when climbing onto the cutting table, check the condition
of slats before standing on them.
Never leave the cabinet door open or covers off when the machine is in operation.
Follow the maintenance procedures as prescribed in the maintenance manual.
0.2 PLASMA ARC RADIATION
The level of arc radiation (visible and invisible!) emitted in dry plasma cutting
(like welding) is very high. To avoid damage to skin and eyes refer below under
eye and skin safety.
It is recommended that the cutting area be prepared in a manner that will reduce
the reflection and transmission of ultraviolet (UV) radiation.
Install protective screens or curtains to reduce UV transmission.
a) Plastic curtains have reflective surfaces and increase the reflected UV

radiation onto operators.
b) Bright rolled aluminium reflects 90% of UV radiation.
c) Stainless steel reflects about 30%.
Paint walls and other surfaces with dark colours to reduce reflection.
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0.2.1 Eye Safety
At any time, wear at least safety glasses to protect your eyes against launched
particles.
When plasma cutting, protect eyes against burns caused by high-intensity UV

light, sparks and hot metal. Do not look into or towards the plasma arc without a
welding helmet capable of protecting both eyes and face. The proper shade of
welding glass for helmets should be selected. Shade:
a) No.10 if the arc current is less than 200 A.
b) No.12 from 200 to 400 A.
c) No. 14 above 400 A.
0.2.2 Skin Safety
To protect skin against burns caused by high-intensity UV light, sparks and hot
metal:
a) Wear protective clothing:
1) gauntlet gloves, safety shoes and hat,
2) flame-retardant clothing which covers all exposed areas, and
3) cuffless trousers to prevent entry of sparks and slag.
b) Do not light oxy torches or pilot torches with a cigarette lighter. Use a long-
stem flint gun.
c) Exercise care when adjusting oxy torch flames.
d) Do not touch the front of the torch when starting it; after cutting allow time
for the torch to cool.
0.3 TOXIC FUME PROTECTION
In all arc or gas welding and cutting operations fumes will be given off.
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GALVANISED METAL OR PAINTED METALS CONTAINING ZINC, LEAD,

CADMIUM OR BERYLLIUM
To protect against the danger of toxic fumes which may be produced during
cutting:
a) Keep the cutting area well-ventilated.
b) Ensure all fume extraction systems are functioning.
c) Wear proper breathing mask when cutting galvanised metal and use proper
ventilation.
d) Do not cut metal or painted metals containing zinc, lead, cadmium or

beryllium unless the operator, and anyone else subject to the fumes, is
wearing respiratory equipment or an air-supplied helmet.
Airborne particles are usually detectable in the form of visible smoke or fumes
and can be removed to a satisfactory level by the use of efficient fume extraction
apparatus or water-shrouded torches.
The main gases to be considered are:
a) Oxides of Nitrogen - produced by the combination of nitrogen and oxygen

in the presence of ultraviolet radiation.
b) Ozone - produced by the action of ultraviolet radiation on oxygen in the air.
c) Phosgene and other gases arising from solvents - ultraviolet and heat will
cause a breakdown of chlorethylene hydrocarbon solvents such as per-
chlorethylene and tri-chlorethylene which are sometimes used as degreasing
agents; toxic gases including phosgene may be formed.
The accepted level of concentrated toxic substances in air is shown in the table
below.
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Gas Gas name Limit values mean weight Limiting value for short
exposure
ppm mg/m3 ppm mg/m3
CO carbon monoxide 50 55 75 82.5
CO2 carbon dioxide 5000 9000 6250 11250
NO nitric oxide 25 30 37.5 45
NO2 nitrous oxide 5 9 5 9
O3 ozone 0.1 0.2 0.3 0.6
COCl2 phosgene 0.05 0.2 0.05 0.2
The more dangerous oxides of nitrogen (NO and NO2) are the most prolific of the
harmful gases even when cutting over water. This fact is important, as cutting
over water and the use of water-shrouded torches dramatically reduce the level of
visual fumes, predominantly oxides of metal which can give the operator a false
sense of gas reduction.
Ozone is a toxic gas and a powerful oxidising agent. It exists in the atmosphere in
very low concentrations. Pure ozone is bluish in colour. At ground level, it is
present in a concentration of 0.025 to 0.045 ppm by volume.
Ozone is also an irritant gas on both short term and long term exposure. It is an
irritant to the eyes and causes inflammation and congestion of the respiratory tract
and, in the event of severe exposure, it produces pulmonary oedema, haemorrhage
and death. The gas can usually be detected as low as 0.05 ppm.
At concentrations above 0.1 ppm there is dryness and irritation of the throat and
upper respiratory tract. At 1 ppm and above, exposures lasting more than 30
minutes result in headache and malaise. Measurable changes in the vital capacity
of the lungs occur following exposure concentrations of 1.5 ppm and above,
lasting a few hours. Incapacitating pulmonary congestion may be caused by daily,
intermittent exposures above 0.5 ppm.
At room temperature, 50% of the present ozone breaks down into oxygen in less
than 30 minutes.
0.3.1 Noise
Noise is unwanted sound that will affect your ability to hear if exposed to high
levels of noise for a long time. The sensible thing to do is to take measures if
noise levels are above 80 dB(A) continuously. The easiest solution is to wear
earmuffs, which are readily available.
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dB (A)
130 threshold of pain
125 close thunder plasma arc
jet take-off cutting noise
100 inside aircraft or subway range
80 busy street
60 ordinary conversation
Low risk noise exposures:
av noise level duration/day

dB(A) (no protection)
80 8 hours
83 4 hours
86 2 hours
89 1 hour
92 30 min.
95 15 min.
98 7.5 min.
101 3.75 min.
104 135 sec.
over 115 Dangerous
TYPICAL NOISE DURING PLASMA CUTTING
Material stainless steel, no water muffler or water table.
Plate Cutting power (kW) Overall noise in dB (2

thickness (refer below) metres from torch)
12 55 98
25 55 104
50 110 (HT400 max 80 103 – 106
kW)
100 165 108 – 111
180 220 112
To calculate the kilowatt output of a plasma system, multiply the arc current by
the arc voltage.
Noise reductions are generally achievable as follows:
Water shroud -6 dB
Water shroud together with water table with water in -10 dB
contact with plate
Underwater cutting -30 dB
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0.4 FIRE PREVENTION
Profile cutting produce hot metal, sparks and slag. Take the following precautions
against fire:
a) Do not operate the oxy fuel torches without spark arrestors.
b) Have fire extinguishers available in the cutting area.
c) Remove combustible material from the immediate cutting area to a distance

of at least 10 metres (35 feet).
d) Quench freshly cut metal or allow metal to cool before handling it or

bringing it into contact with combustible materials.
e) Ventilate potentially flammable atmospheres before cutting with a plasma

system; never operate the plasma system in an atmosphere which contains
heavy concentrations of dust, flammable gas or combustible liquid vapours.
0.5 ELECTRIC SHOCK PREVENTION
Open circuit voltages up to 400 V are possible and high frequency current at high
voltage is used to initiate the arc. In other words, the machine uses high voltages
that can kill. The following precautions should be observed:
a) All installation and maintenance should be carried out by qualified electrical

personnel.
b) Switch off and lock out main disconnect switch before opening the cabinet.
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c) Be aware that live parts may be present even though the main disconnect
switch is in its off position.
d) Never bypass the safety interlock circuit.
e) Do not remove safety covers of components; if these have been removed

take care to replace them prior to powering up again.
f) All protective earth wires must remain connected at all times.
g) Do not clean the machine or plasma power supplies with a water hose.
The quality of water used for plasma systems is very important because it could
cause an electrical leak to earth. Electrical resistivity of the water must exceed
100 kΩcm. Hard water can lead to scaling and the blocking of waterways and the
burning out of the torch. Check water specifications for individual plasma
systems.
0.6 GROUNDING
DO NOT DISCONNECT EARTH CABLES OR WORK CABLES
0.7 EXPLOSION PREVENTION
Plasma and oxy fuel cutting systems use compressed gas. Proper precautions
must be observed when handling and using compressed gas equipment and
cylinders.
When cutting with the plasma system:
a) Do not cut in atmospheres containing explosive dust or vapours
b) Do not cut pressurised cylinders or any closed container.
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0.7.1 Pressure Regulators
Maintain all pressure regulators in proper working condition, faulty regulators can
cause damage or operator injury and must be serviced by trained repair
technicians.
Never use a regulator for any gas other than that for which it is intended.
Never use a regulator that leaks, creeps excessively or is physically damaged in

any way.
Never attempt to lubricate a regulator with oil or grease.
0.7.2 Compressed Gas Cylinders
Never use a cylinder that leaks or is physically damaged.
Never use a cylinder that is not upright and secured in place.
Never move or transport a cylinder without the protective valve cover in place.
Never use a gas cylinder or its contents for any purpose other than that for which
it is intended.
Never lubricate cylinder valves with oil or grease.
Never allow electrical contact between the plasma arc and a cylinder.
Never expose cylinders to excessive heat, sparks, slag or open flame.
Never use hammers, wrenches or other tools to open stuck cylinder valves.
0.7.3 Hoses
Label and colour code all gas hoses in order to clearly identify the type of gas in
each hose, consult applicable national or local codes.
Never use the oxygen hose for any gas other than oxygen.
Replace hose that is damaged by physical abuse or by sparks, heat or open flame.
Coil excess hose and place it out of the way to prevent damage and tripping
danger.
Examine hoses at regular intervals for leaks, wear, loose connections or other
hazards.
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Keep hose lengths to a minimum to prevent damage, reduce pressure drop and to
prevent possible volume flow restriction.
0.8 SAFETY REMINDERS
Never bypass or shortcut the safety interlocks on any of the plasma system units.
Operators should familiarise themselves with the location of safety switches,

mains switches and valves, etc., refer chapter introduction.
0.8.1 Precautions Summary
The dangers from toxic gases will vary dramatically from installation to
installation with such factors as:
a) use of water table,
b) submersed cutting,
c) water spray & water muffler use around plasma torch,
d) air movement and confinement,
e) use of fume extraction table,
f) operator proximity,
g) cutting time vs. idle time,
h) number of cutting torches, and/or
i) atmospheric conditions.
Personal particulate respirators, welding helmets, earmuffs, protective dark

clothing and gloves etc. can reduce the damaging effects of all arc welding and
cutting equipment.
Although most of the gases given off by plasma arc cutting disperse quickly,
plenty of ventilation and air movement past the operator is recommended.
Fume extraction worktables, carriage fume extraction, and water tank type tables,
particularly when used in conjunction with plasma torch water-shrouds can
minimise the hazards.
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1. GENERAL NOTES
The FARLEY HERCULES is supplied to satisfy a variety of requirements. This
manual covers some of the current options, not all of which may apply to an
individual machine.
For components not manufactured by FARLEY refer to manufacturers literature

supplied with the machine.
Item numbers shown with a prefix, e.g. (Item s2) refer to the isometric sketch of
the machine. Item numbers shown without a prefix, e.g. (Item 2) refer to drawing
extracts as indicated.
1.1 SAFETY
WARNING
BEFORE CLEANING, LUBRICATING OR MAKING ADJUSTMENTS TO THE

MACHINE, IT IS IMPORTANT THAT THE ELECTRIC POWER BE
DISCONNECTED BY PRESSING ONE OF THE LOCK OUT STOP BUTTONS.
2. DAILY CLEANING AND CHECKING
2.1 GENERAL
Clean outside surfaces of beam (Item s2), cabinet (Item s4), drill box (Item s14)
and torch boxes (Items s15, s16). Use a clean cloth. Do not use solvents or
abrasives.
2.1.1 Rail axis racks
Main drive rack Item s31, Slave drive rack (not shown on isometric),
2.1.2 Beam axis rack (Item s19)
Clean with compressed air. Alternatively use a vacuum cleaner and a brush.
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2.1.3 Beam axis linear rails
(Item s21) Keep linear rails clean always. Use a clean cloth and an aerosol spray
such as 'WD40'.
2.1.4 Swarf
Remove swarf as it is produced from around the foot.
2.1.5 Rail wipers, drive side (Item s30), Slave side (Item s23)
Ensure that the rail wipers are always effective. Adjust to produce a stress in the
blade, as shown in Fig. 1 Item 6. Replace wiper blades when they are worn.
3 2
3 4
RAIL
Figure 1 Wiper Assembly
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3. WEEKLY CLEANING AND LUBRICATION
3.1 BEAM AXIS LINEAR BEARINGS (ITEM S24)
Lubricate through grease nipples.
3.2 RAIL AXIS RACKS, BEAM AXIS RACK
After cleaning, lubricate each rack with Molybond aerosol lubricant '122L'. Wipe
off surplus lubricant from adjacent surfaces. Do not use oil or grease on racks or
pinions.
4. MONTHLY SERVICE
4.1 SUPPORT WHEEL BEARINGS, DRIVE SIDE (ITEM S1), SLAVE SIDE
(ITEM S22)
Lubricate through grease nipples (Fig. 2, Item 5, Fig. 3, Item 5).
4.2 RAIL GUIDE ROLLERS
Drive side (Item s29) - Refer Fig. 2, Item 8.
Slave side (not shown on isometric) - Refer Fig. 4, Item 15.
These rollers are sealed and packed with grease and need no further lubrication for
the life of the bearing.
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8 15
RAIL
1.5 ECCENTRIC
Figure 2 – Support assembly, drive side
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2
IDLE LEG
3
9
4
10
5
11 7
RAIL
Figure 3 – Support assy. slave side
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BEAM
IDLE LEG
7
DRILL ø30 THRU
9 2 HOLES
1
25
13 11
11 10
14
15
15
12
RAIL 16 17
18 25
SECTION A-A
Figure 4 – Guide rollers slave side
4.3 RAIL AXIS DRIVE GEAR BOXES/BEAM AXIS DRIVE GEAR BOX
(Main drive Item s26, Slave drive not shown on isometric)
Check the oil level in each gear box through oil level window (Fig. 5 Item 9).
If the level has dropped, locate the point of leakage. Pending repair of the leak,
top up with Castrol Hyspin AWS 100 or equivalent. The oil level window on the
rail axis gear boxes face towards the table. The oil level window on the beam axis
gear box is visible through a hole in the left hand side the drill box.
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Figure 5 – Inspection window, gear box
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CATERPILLAR
8 WAY DIVIDER
VALVE
4 mm HP
GREASE NIPPLE NYLON TUBE
(typ)
TOP BWG
L/BRG L/BRG BALL SCREW
BALL
NUT
Z AXIS CARRIAGE
BOTTOM BWG
L/BRG L/BRG
BALL SCREW
Figure 6 – Drillbox lubrication
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4.4 LUBRICATION POINTS WITHIN THE DRILL BOX
Obtain access through the removable panels on the front and left hand side of the
drill box. Clean the linear rails (Item s11) and the ball screw for the Z axis (Item
s10) with a clean cloth and 'WD40'. Shift the spindle carriage to expose all
surfaces.
Apply grease to the ball screw, linear bearings and ball screw top and bottom
bearings through the Tecalemit grease divider valve (Fig. 6) located within the
Drill box.
4.5 TORCH LIFTER LINEAR RAILS AND BEARINGS
(eg. Fig. 10, Items 5, 18)
Remove front covers of torch boxes and replace after service. Clean each linear
rail with a clean cloth and WD40. Shift lifter to expose all surfaces.
Lubricate each linear bearing through grease nipple.
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65
46
64
25:1
101.6
TYP
63
45
23
24
3
62
1
50
25
26
47
27
18
19
68 67
60
48
51
52
53
54
59
58
49
61
57 56 55
Figure 7 – Toolchanger linear rails and bearings
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4.6 TOOL CHANGER LUBRICATION
The toolchanger requires chain lubrication and checking chain tension.
The toolholders are on a pitch of 101.6 mm (4.0 inches). When replacing a tool
holder, ensure the replaced holder is positioned on the chain at this pitch distance
from the adjacent holder. A suitable gauge may have to be made to facilitate the
fitting operation.
A safety interlock switch is fitted to the door of the toolchanger. When the door is
opened, the toolchanger is unable to be indexed.
The toolchanger can be index be pressing the green button mounted on the
junction box adjacent to the toolchanger assembly. An emergency stop button is
also mounted on the junction box.
4.7 BEAM AXIS CATERPILLARS (ITEMS S9, S17), CATERPILLAR TRAYS

(ITEM S18)
Remove dust with a brush and a vacuum cleaner.
4.8 CABINET AIR CONDITIONER (ITEM S5)
Check operation. Maximum allowable temperature inside the cabinet is 40ºC.
4.9 POWER CABINET FAN UNIT AND AIR OUTLET FILTER - (RITTAL
3165, 3160)
Remove filter mats from the Fan unit and Air outlet filter. Clean with clean, dry
compressed air or with water and detergent, followed by thorough drying.
Replace mats annually.
4.10 LOCK OUT STOP SWITCHES
Check the operation of the lock out stop switches on the panel (Item s3), at the end
of the beam and at the rear of the machine.
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5. THREE MONTHLY SERVICE
5.1 CONTROL CABINET (ITEM S4), CONTROL PANEL (ITEM S3)
Make a visual check. Check electrical connections.
5.2 CATERPILLARS, CABLES AND HOSES FOR BOTH AXES (ITEMS S8,
S9, S17)
Check condition. Check for fluid leaks.
5.3 FEED HOLD AND EMERGENCY STOP LIMIT SWITCHES

(DESCRIPTION AND TESTING)
Feed hold and emergency stop limit switches are fitted to the beam for the Rail
axis and to the drill box and last torch box for the Beam axis. On approaching a
travel limit, motion will normally cease when the feed hold switch contacts the
cam on the rail or beam. If motion continues, the emergency stop switch will then
contact the cam to disable the servodrive.
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2
BEAM - DRIVE SIDE
3
4 5
4 5
7 8
TA P M 6 O N A S
6 H O LE S
9 TYP
Figure 8 – Rail limit switches
For further information regarding the arrangement of the limit switches, refer to
the limit switch assembly drawings supplied with the machine.
5.3.1 Feed hold limit switches
To test, put all tools in the "up" position. Engage the bar clamp(s) for the slave
torch box(es) if fitted. Drive towards each rail axis and beam axis limit in turn.
Reduce speed to 2 metres per minute on approaching the travel limit and confirm
that motion ceases when the feedhold switch strikes the cam. Be prepared to use
the lock out stop switch on the panel if both feed hold switch and emergency stop
switch fail to stop the motion.
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EMERGENCY
- FEED HOLD
80
LINEAR
CABINET
BEARING
END OF RAIL
Figure 9 – Beam limit switches
5.3.2 Emergency stop limit switches
No test procedure is specified. Refer to the description under feed hold switches.
To resume operation after an emergency stop, push the beam or the torch box(es)
back so that the switch operator comes off the cam.
5.4 CRASH PROTECTION LIMIT SWITCHES (DESCRIPTION AND

TESTING)
For information regarding the arrangement of limit switches and the location of
protected zones, refer to the limit switch assembly drawings supplied with the
machine.
5.4.1 Rail axis
There is a limit switch to provide table crash protection for the drilling foot and
for the torches at the front end wall of the table.
To test for the foot, drive the beam so that the foot is within 50 mm. of the front
end wall of the table. Check that the foot may not be put down in this location.
To test for the torches, with each tool down in turn, drive the beam towards the
front end wall of the table. Reduce speed to 2 metres per minute on approaching
the protected zone that begins 195 mm from the front end wall of the table. As the
tool is about to enter the protected zone, motion should cease and the tool should
retract. Be prepared to use the lock out stop switch on the front panel if the beam
keeps going.
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Note that the crash protection switches do not disable the servodrives, so that as
soon as the torch lifter reaches the top limit, motion may proceed.
5.5 FOOT PROTECTION
There is a limit switch to provide table crash protection for the drilling foot on the
cabinet side of the table. The protected zone normally begins 420 mm from the
cabinet side wall of the table
To test, drive the drill box so that the foot is within 50 mm of the table wall.
Check that the foot may not be put down in this location.
5.6 TORCH PROTECTION
The torch boxes are fitted with limit switches, one for each tool, to prevent a
collision between the tool and a side wall or walls of the table.
To test, with each tool down in turn, drive towards each side of the table. Reduce
speed to 2 metres per minute on approaching the protected zone that begins 170
mm from the side wall of the table. When the tool is about to enter the protected
zone motion should cease and the tool should retract. Be prepared to use the
emergency stop switch if axis motion continues. In some cases the limit of travel
may be reached before the torch reaches the protected zone.
As for the Rail axis, the crash protection switches do not disable the servodrives,
so that as soon as the torch lifter reaches the top limit, motion may proceed.
5.7 MAGNETIC BREAK AWAY JOINT(S)
If there is a collision between a torch and some object, the break away joint will
separate and stop the machine motion. Confirm that there can be no axis motion if
any torch is removed at the break away joint.
5.8 TORCH BOXES (ITEMS S15, S16)
Remove torch box covers and replace after service.
5.8.1 General
Make a visual check of all components. Check for fluid leaks. Check condition
of hoses and cables.
Maintenance Manual
28
2005 Hercules
15
2 3
2 3
16
18
4
17 19
5
20
6 3 2
7 21 3
BEAM
8 9
256
199
170
14 13 12 11 10
421
Figure 10 – Lifter assembly (typical)
Maintenance Manual
29
2005 Hercules
5.8.2 Lifter bands (Fig. 10, Item 19)
Check condition and replace if worn.
5.8.3 Top limit switches (e.g. Fig. 10, Item 16)
Drive the lifter upwards and allow it to stop on the top limit switch. Confirm that
the linear bearing is clear of the end stop. If necessary, adjust the position of the
switch.
5.8.4 Band break limit switches (Fig. 10, Items 15 and 16)
If a torch lifter band breaks, a feed hold is applied to the machine. To test each
switch, support the lifter with a piece of cord or in a similar way so that the band
goes slack. Confirm that in this condition, the machine is on feed hold.
5.9 AXIS DRIVE MOTORS (E.G. ITEMS S13, S27) , SPINDLE DRIVE
MOTOR (ITEM S25)
The AC Servomotors used on this machine normally require no maintenance. If

there is a problem, consult Farley Service.
5.10 CABINET AIR CONDITIONER (ITEM S5)
Check the condition of the ambient air filter of the air conditioner. Follow the
cleaning procedure described in the McLean Midwest Instruction Manual. Recoat
with "Filtercoat". (Refer spare parts, page 27).
6. ADJUSTMENTS
6.1 RAIL GUIDE ROLLERS, DRIVE SIDE (ITEM S29), SEE ALSO FIG. 2.
6.1.1 Description
There are two pairs of rail guide rollers on the drive side of the machine. The
roller on the rack side of the rail is mounted on a concentric shaft (Item 15). The
roller on the outside is mounted on an eccentric shaft (Item 7). Adjustment is
made to produce a slight preload between the pairs of rollers.
Maintenance Manual
30
2005 Hercules
6
75
40
32 mm AF
ECCENTRIC
SHAFT
RAIL COVER NOT SHOWN
Figure 11 – Support wheel assy
6.1.2 Adjustment procedure
Loosen screw (Item 6) and with a thin spanner, 32 AF, turn the eccentric shaft
until the guide roller is firm against the rail. Tighten screw (Item 6) whilst
maintaining torque.
Maintenance Manual
31
2005 Hercules
6.2 AXIS DRIVES
The Rail axis Main drive and Beam axis drive used on the Farley Hercules are
designed to give axis motion without backlash.
APPLY LIQUID GASKET

FOR SEALING
GEAR RATIO 8.29407 : 1 18 17 16 14 44 49 57 46 15 12

24
PITCH 16.66613 mm PER REV. OF MOTOR
APPLY LIQUID GASKET
FOR SEALING
27 3 PLS
51
21 49
59
13 44
19
20
28 SPU R G EAR 22T

M O D ULE - 2
44 PC D
25
26 HE LICA L GEAR
M O DULE 2
108.542 P CD
61
56 35
H ELIC AL GEAR
M O D ULE 2
39.26 PC D
55
H ELIC AL GEAR
M O D ULE 2
39.26 PC D
SEE PLUNGER ASSY 20
H ELIC AL GEAR
19
32 M O D ULE 2
108.542 PC D
61
57T
38
SPU R G EAR 22T

M O D ULE - 2
44 PC D
19T
SIEMENS 1FK6083-6AF71-1TGO
STATIC TORQUE 16 Nm, 3000 RPM MAX
37 36 41 39 18 44 49 15 46 47 48 49 44 35 51 52 53 54
40
Figure 12 – Drive gear box, cross section
6.3 AXIS DRIVES (EG. ITEM S26), REFER FIG. 12.
Servomotor (Item 37) drives Input Shaft (Item 55) through Input Pinion (Item 41)
and Input Pulley (Item 13). The Input Shaft has machined on it two helical gears
of opposite hand that mesh with two Helical Gears. Each Helical Gear is fitted to
an Output Pinion Shaft (Item 15). The two Output Pinions mesh with the rail axis
rack.
Maintenance Manual
32
2005 Hercules
The Input Shaft is pushed downwards by Plunger assy. (Fig. 13) so that the Output
Pinions tend to rotate in opposite directions, thus eliminating backlash. The axial
loading on the Input Shaft is large enough to ensure that there is no backlash under
conditions of maximum acceleration or deceleration.
Maintenance Manual
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2005 Hercules
DEFLECTION
SETTING PROCEDURE:
mm
- ASSEMBLE WITH THE APPROPRIATE SPRING
40 MAX - SCREW CAP DOWN UNTIL IT JUST TOUCHES THE SPRING
- MEASURE THE HEIGHT "H"
30 - SCREW CAP DOWN BY THE AMOUNT REQUIRED SEE CHART
- LOCK NUT IN POSITION
20
1
10
2 3
LOAD kg
100
200
300
ITEM 2- DIE SPRING KEY NO 22645
A.S.P.- 38.5 HOLE X 101.6 F.L. M.H.D.
SPRING RATE 8.56 kg/mm
H
DEFLECTION
mm
5
30
MAX 6 7 8
20
10
9
Figure 13 – Plunger assembly. rail axis gear box

100
200
300
400
500
600
700
LOAD kg
GEAR BOX PRESSURE PLATE
ITEM 3 - DIE SPRING KEY NO 22646
A.S.P.- 38.5 HOLE X 101.6 F.L. X.H.D.
SPRING RATE 30.57 kg/mm
34
Maintenance Manual
2005 Hercules
6.3.1 Beam axis drive (Item s12)
The Beam axis drive uses the same Gearbox and operates in the same way as the
Rail axis drives. The Input Shaft is pushed downwards by Plunger assembly.
WARNING
NEVER REMOVE THE PLUNGER ASSEMBLY
WITHOUT UNLOADING THE SPRING
FAILURE TO DO SO WILL RESULT IN INJURY TO PERSONNEL

AND/OR DAMAGE TO EQUIPMENT
Maintenance Manual
35
2005 Hercules
10 11 22
2 33
2 34
38
29 3
23 8
36
9 1
Figure 14 – Gearbox, top view
Maintenance Manual
36
2005 Hercules
6.3.2 Rail axis Slave drive - Description
The gearbox with attached Adapter plate (Item 2) is fixed to Mounting plate (Item
1) with screws and washers (Items 10, 11) fitted through slotted holes. The
Mounting plate is supported from the beam of the machine by linear bearings
(Item 4) and Linear rails (Item 3).
This arrangement allows the assembly to move in the direction of the beam axis.
Guide rollers, one fixed and one adjustable are fixed to the Mounting plate. See
Fig. 4.
BILLET
20 19 3 4 1 10 11 2
A
Figure 15 – Slave assembly (detail)
6.3.3 Adjustments
Only the guide rollers are Operator adjustable. The gearbox drives should only be
adjusted by FARLEY LASER LAB Service personnel, NEVER by the Operator.
6.3.3.1 Rail guide rollers (Fig. 4)
Loosen screw (Item 13) and with a thin spanner, 32 AF, turn the eccentric shaft
with a torque of 5 -10 Nm. Tighten screw (Item 13) whilst maintaining torque.
Maintenance Manual
37
2005 Hercules
7. RECOMMENDED GREASE
For all greasing, use SHELL Alvania No EP2 or equivalent.
8. SPARE PARTS (RECOMMENDED TO BE HELD

IN STOCK)
Description Farley Drwg. No. Length Quantity
or Key No. metres
Blade Wiper 583166 8
Lifter Band 16 mm 22745 1 1
Filtercoat 1 Pint Manual Spray 13769 1
Tool holder 20620 20
Maintenance Manual
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2005 Hercules
9. ITEM NUMBER IDENTIFICATION

item item name
1 support wheel, drive side
2 beam structure
3 control panel
4 control cabinet
5 air conditioner
6 fume extraction duct
7 caterpillar tray, rail axis
8 caterpillar, rail axis
9 caterpillar, beam axis
10 ball screw, Z axis
11
12
linear rails, Z axis
drive gear box, beam axis
EMERGENCY stops
13 drive motor, beam axis
14 drill carriage
15 torch carriage
16 torch carriage
17 caterpillar, beam axis
18 caterpillar tray, beam axis
19 rack, beam axis
20 fume extraction duct, beam
axis
21 linear rails, beam axis
22 support wheel, slave side
23 rail wiper, slave side
24 linear bearing, beam axis
25 spindle drive motor
26 drive, rail axis
27 motor, rail axis
28 linear rail, tool changer
29 rail guide rollers, drive side
30
31
rail wipers, drive side
rack, rail axis
EMERGENCY
stop
Figure 16 - - Isometric View of a Typical HERCULES with Item Numbers
Maintenance Manual
39

Hercules 2005: Operator Manual

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OPERATOR MANUAL

0. SAFETY ISSUES ................................................................................................................ 5

Figure 13 – Plunger assembly. rail axis gear box..................................................................... 34

0.1 MACHINE SAFETY

Stop the machine if anyone's personal safety is at risk.

When the machine is to be left unsupervised actuate the feedhold or emergency

Never stand on the machine rails.

Never work on or near the machine when it is operating.

Follow the maintenance procedures as prescribed in the maintenance manual.

0.2 PLASMA ARC RADIATION

Install protective screens or curtains to reduce UV transmission.

a) Plastic curtains have reflective surfaces and increase the reflected UV

b) Bright rolled aluminium reflects 90% of UV radiation.

c) Stainless steel reflects about 30%.

0.2.1 Eye Safety

When plasma cutting, protect eyes against burns caused by high-intensity UV

a) No.10 if the arc current is less than 200 A.

b) No.12 from 200 to 400 A.

c) No. 14 above 400 A.

0.2.2 Skin Safety

a) Wear protective clothing:

1) gauntlet gloves, safety shoes and hat,

2) flame-retardant clothing which covers all exposed areas, and

3) cuffless trousers to prevent entry of sparks and slag.

c) Exercise care when adjusting oxy torch flames.

0.3 TOXIC FUME PROTECTION

GALVANISED METAL OR PAINTED METALS CONTAINING ZINC, LEAD,

a) Keep the cutting area well-ventilated.

b) Ensure all fume extraction systems are functioning.

d) Do not cut metal or painted metals containing zinc, lead, cadmium or

The main gases to be considered are:

a) Oxides of Nitrogen - produced by the combination of nitrogen and oxygen

b) Ozone - produced by the action of ultraviolet radiation on oxygen in the air.

Low risk noise exposures:

av noise level duration/day

TYPICAL NOISE DURING PLASMA CUTTING

Material stainless steel, no water muffler or water table.

Plate Cutting power (kW) Overall noise in dB (2

Noise reductions are generally achievable as follows:

0.4 FIRE PREVENTION

a) Do not operate the oxy fuel torches without spark arrestors.

b) Have fire extinguishers available in the cutting area.

c) Remove combustible material from the immediate cutting area to a distance

d) Quench freshly cut metal or allow metal to cool before handling it or

e) Ventilate potentially flammable atmospheres before cutting with a plasma

0.5 ELECTRIC SHOCK PREVENTION

a) All installation and maintenance should be carried out by qualified electrical

d) Never bypass the safety interlock circuit.

e) Do not remove safety covers of components; if these have been removed

f) All protective earth wires must remain connected at all times.

DO NOT DISCONNECT EARTH CABLES OR WORK CABLES

0.7 EXPLOSION PREVENTION

When cutting with the plasma system:

a) Do not cut in atmospheres containing explosive dust or vapours

b) Do not cut pressurised cylinders or any closed container.

0.7.1 Pressure Regulators

Never use a regulator that leaks, creeps excessively or is physically damaged in

Never attempt to lubricate a regulator with oil or grease.

0.7.2 Compressed Gas Cylinders

Never use a cylinder that leaks or is physically damaged.

Never use a cylinder that is not upright and secured in place.

Never lubricate cylinder valves with oil or grease.