MAN TWIN1213R0en1 PDF

MACHINING CENTER
Mod.: TWIN
Use and maintenance instruction

manual
(translation of original instructions)
Document: MAN_ TWIN1213R0en

Edition: 12/2013
Rev.: 0 Data: 16/12/2013
TWIN – Use and maintenance instruction manual
Instruction manual for the machine models and the versions listed below.
MACHINE MODELS AND VERSIONS DESCRIBED IN THE MANUAL

MODEL DESCRIPTION
Cap. 0
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GENERAL INDEX
General index 0
Foreword 1
Safety information 2
Machine description and technical data 3
Installation 4
Controls and use 5
Maintenance 6
Attached documents and diagrams 7
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“Page intentionally left blank”
Cap. 0
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CHAPTER 1 – Foreword
CHAPTER
1 Foreword
Chap. 1
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INDEX
1 Foreword ...................................................................................................................... 1
1.1 Objective of the manual ...........................................................................................................................4
1.2 Manual addressees ...................................................................................................................................5
1.2.1 Description of symbols, deadlines and abbreviations adopted ................................................................... 7
1.2.2 Symbols adopted, glossary of terms and illustrations ................................................................................ 7
1.3 Glossary of safety terms ..........................................................................................................................9
1.4 Use and conservation of documentation .............................................................................................10
1.5 Update of the manual .............................................................................................................................10
1.6 How to request additional copies .........................................................................................................11
1.7 Manufacturer’s Identification and Contact Details ..............................................................................11
1.8 Customer service ....................................................................................................................................12
1.8.1 How to request spare parts ...................................................................................................................... 13
Chap. 1
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Chap. 1
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1.1 Objective of the manual
As foreseen in the Machinery Directive 2006/42/EC, this manual provides information on safety and the
life phases of the machine (transport, installation, use, maintenance, dismantling).
Read carefully and understand this technical publication before intervening at operational level
on the machine or performing adjustment and/or maintenance interventions.
Exclusively abide by the instructions provided and in case of doubt always contact the manufacturer.
This manual provides basic information that the user must know before using the machine. Furthermore,
it contains information on machine maintenance needed to keep it efficient and safe over time.
For proper machine use, please also consult the Software User Manual and any attachments.
The configuration of certain parts or devices described or illustrated in the manual may differ from the
ones supplied with machine without, however, jeopardising its understanding.
Chap. 1
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1.2 Manual addressees
All operations described will be accompanied by a symbol (pictograph) corresponding to the operator
considered more suitable for the task; the symbols at the head of each paragraph correspond to the
addresses of the information provided. Please find below the instructions necessary for the identification
of the different professional figures.
A - Operators
Personnel with no specific skills capable of performing only simple tasks, such as
operating the machine using the controls located on the pushbutton panel, loading
and unloading the materials used in production with installed and enabled
protection guards and service settings.
B - Mechanical maintenance men

Personnel with specific mechanical skills capable of carrying out the tasks of the
"operators" and work with the machine in standard operating conditions with
disabled protection guards for maintenance and/or repair work. Not authorised to
work on the electrical system.
C - Electric/electronic maintenance men

Personnel with specific electrical skills capable of carrying out the tasks of the
"operators" and work with the machine in standard operating conditions with
disabled protection guards for maintenance and/or repair work. Not authorised to
work on mechanical parts.
D - Mechanical support technicians

Qualified personnel with specific mechanical skills capable of carrying out the
tasks of item B and further, they can skilfully make any possible settings and/or
replace mechanical parts. Not authorised to work on the electrical system.
E - Electrical/electronic support technicians

Qualified personnel with specific electrical/electronic skills capable of carrying out
the tasks of item C, work with the machine in standard operating conditions with
disabled protection guards and skilfully carry out any adjustments and/or
replacements of electrical/electronic parts. Not authorised to work on mechanical
units.
F- Lifting and handling equipment operator

Operator authorised to use devices designed to lif and handle materials and
machinery (strictly following the manufacturer’s instructions), in compliance with
the regulations in force in the machine user’s country.
Chap. 1
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Certain pieces of information of the manual may address non-professional figures (e.g. cleaning
personnel of the premises where the machine is installed) who are not authorised to operate the
machine, but may be close to the premises for different reasons.
G – Common Individual
Non-qualified individuals who are not suitable for carrying out any tasks intended
for the professionals described under items A, B, C, D, E, F and thus not
authorised to operate the machine.
INFORMATION!
Remember that information, training and supervision of common persons (par. G) is up to the
employer.
Chap. 1
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1.2.1 Description of symbols, deadlines and abbreviations adopted
For optimum machine use, we recommend you are familiar with the terms and symbols contained in the
manual.
1.2.2 Symbols adopted, glossary of terms and illustrations
Information addressees
Refer to paragraph “1.2 Addressees of the manual”
DANGER, WARNING and INFORMATION notes

DANGER!
The information marked by the symbol on the left and this style denote dangerous situations for the
exposed individual.
WARNING!
The information marked by the symbol on the left and this style denote situations that may damage the
machine.
INFORMATION!
The information marked by the symbol on the left and this style denote useful suggestions and
recommendations for the user.
ENVIRONMENTAL INFORMATION!
The information marked by the symbol on the left refer to environment-related information, such as
handling hazardous substances, waste or recycling of the used materials produced by the machine.
Information symbols on the machine

Pictograms are located in specific positions on the machine to indicate the presence of residual risks
during machine use. Please refer to paragraphs “2.4.1 and 2.4.2 for a comprehensive explanation of the
these symbols.
Chap. 1
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INFORMATION!
The colours of the photos shown this manual illustrating the machine's structure or
constituting parts may differ from the ones installed on your machine. Remember that the
content of this manual refers to technically comparable machines that represent the machine
you possess and that different colours do not mean that the information provided is incorrect,
except for the cases in which a colour define aspects concerning the safety of exposed
persons.
If the illustrations of this manual are used to explain certain machine functions, they could differ from
the functions of your machine or they could be incomplete. If necessary, and in addition to the
instructions of this manual, it is advisable to consult the specific design of the component or unit on
which intervention is required. For the specific design (e.g. installation layout, assembly unit etc.)
please address the manufacturer.
INFORMATION!
For the sake of clarity, the machine is illustrated without panels and/or protection devices in
this technical manual. Do not use the machine when protection devices are dismantled,
removed and/or disabled.
Chap. 1
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1.3 Glossary of safety terms
In compliance with European Directives 89/391/EEC, 89/654/EEC, 89/655/EEC, 89/656/EEC,

90/269/EEC, 90/270/EEC, 90/394/EEC, 90/679/EEC, 93/88/EEC, 95/63/EEC, 97/42/EEC, 98/24/EEC,
99/38/EEC and 2001/45/V concerning the improvement of workers’ safety and health during work,
please find below the definitions used in this instruction manual.
PERSONAL PROTECTIVE EQUIPMENT (PPE)

Personal protective equipment (PPE) is equipment worn by the operator to minimize exposure to a
variety of safety and health hazards at work, as well as any complement or accessory serving the same
purpose.
The following are not pieces of personal protective equipment:
• Work cloths and overalls that do not specifically protect workers’ safety and health;
• Equipment of aid and rescue services;
• Personal protective equipment of armed forces, police forces and service personnel for keeping
public order;
• Personal protective equipment of means of road transport;
• Sports materials;
• Self-defense and determent materials;
• Portable devices for the identification and reporting of risks and harmful factors.
WORKER
A person who is hired by an employer to perform labour, except people in charge of domestic and family
services, even with a special subordinate work relationship.
Partners of cooperatives or companies who perform their job on behalf of companies and organisations
and users of school, university and professional guidance and training services that have started working
for employers to facilitate or optimize their professional choices are intended as workers.
Students of educational and university institutes and the participants of professional training courses
where one can use laboratories, machines, devices and work equipment in general; chemical, physical
and biological agents are also considered workers. The forenamed subjects are not included in the
calculation of the number of workers for whom particular obligations arise in accordance with this decree.
EMPLOYER
The person who holds an employment relationship with the worker or, in any case, the subject who,
depending on the company type and organisation, is responsible for the company or the productive unit
and has decision making powers and expenses.
Chap. 1
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1.4 Use and conservation of documentation
The consultation of this manual and the documentation provided with the machine is of paramount
importance in order to train users on how to use the machine correctly for productive purposes, on how
to abide by the safety standards and understand the residual risks in the product. The user is required to
know the content of the manual concerning the duties he/she is to perform.
Even if the manual provides information on how to use the machine correctly and residual risks
connected with machine use, it cannot replace the user’s experience; users must necessarily be
“experts” who are familiar with the sector and related operational and safety procedures.
The documentation delivered and its content must be checked upon receipt and upon completion of the
training session.
Keep the manual and all attached publications in a place that can be easily accessed by all users.
The information contained in this manual is property of Paolino Bacci S.r.L.; total or partial reproduction
is forbidden without prior authorisation. If you need additional copies of the documentation intended for
machinery users, please send a request to Paolino Bacci S.r.L.
If doubts arise during consultation of this manual, please contact Paolino Bacci S.r.L. before performing
any operation.
Paolino Bacci S.r.L. reserves the right to modify the characteristics of the product and content of this
manual without prior notice.
Paolino Bacci S.r.L. reserves the right to provide a soft copy of the manual. The publication on file is in
PDF (Portable Document File) format; for consultation you need to set up the Adobe® Acrobat®
Reader™ software beforehand. Instructions on installation and use of the Adobe® Acrobat® Reader™
software are available together with the set up file. Further information can be found on the website of
Adobe Systems Incorporate, from which it is possible to download a free version of the Adobe®
Acrobat® Reader™ software.
1.5 Update of the manual
If modifications or updates are performed during the lifecycle of the machine by Paolino Bacci S.r.L., a
reviewed copy of this document will be sent to the customer. All contractual copies of the customer will
be destroyed and replaced upon prior contact with Paolino Bacci S.r.L..
Chap. 1
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1.6 How to request additional copies
Further copies of this document apart from the contractual ones are available upon request by sending a
regular purchase order to Paolino Bacci S.r.L..
1.7 Manufacturer’s Identification and Contact Details
Company name:
Paolino Bacci S.r.l.
Address:
Viale Palermo, 32
56021 CASCINA (PI) - ITALIA
Tel. :
+39 050 754 91
Fax:
+39 050 754 975
Fax assistance:
+39 050 975
E-mail – general information:

bacci.info@bacci.com
E-mail – assistance::
service@bacci.com
E-mail – spare parts:

service@bacci.com
Website:
www.bacci.com
Chap. 1
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1.8 Customer service
To guarantee our customers optimum use of the product purchased, Paolino Bacci S.r.L. provides the
following technical support services:
Customer service:
Office services provided by qualified operators, who are able to diagnose and decide upon the
interventions required to restore damaged and malfunctioning machinery components. These services
are provided mainly over the phone; they provide assistance to maintenance technicians during
troubleshooting and repair works. Technical assistance uses the diagnostic service provided via
MODEM if it is installed on the machinery.
Spare parts support:

Office service provided by qualified operators who can be contacted to request spare parts for the
machinery.
Support services are open during the working hours and days mentioned in the following tables. The
office hours outlined in the tables below are based on the time zone of Rome (GMT+1,00 h).
WEEKDAYS (FROM MONDAY TO FRIDAY)

HOURS ACTIVE SERVICE
Customer service
8.00 – 18.00 (GMT + 1.00h)
Spare parts support
INFORMATION!
When you require a support/assistance service, please remember to provide the data
indicated on the identification plate of your machine.
INFORMATION!
Ordinary maintenance interventions are up to the user’s personnel. Support interventions on
the machine's systems (electrical, pneumatic etc.) must be performed by qualified personnel
duly authorised by Paolino Bacci S.r.l.
Chap. 1
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1.8.1 How to request spare parts

To order spare part(s) please contact the spare parts support unit and remember to specify the following
data:
• Serial number.
• Machine type.
• Warehouse code* Paolino Bacci S.r.L.
• Description*.
• Quantity*.
INFORMATION!
The code numbers and description of the parts to order are mentioned in the “list of spare
parts" or in the wiring, pneumatic and hydraulic diagrams provided with the machine. Should
these data not be available, contact Paolino Bacci S.r.L.
DANGER!
You must use original spare parts. The replacement of parts with non-original parts or parts
that have not been previously authorised by Paolino Bacci S.r.L. is at the customer's own
risk and shall result in the immediate expiry of the warranty and of the certification pursuant
to applicable community directives.
Machine performance and safe operation are guaranteed with the use of original parts as
provided in the original project.
Paolino Bacci S.r.L. cannot be held liable for malfunctioning, damages or injuries caused by
the use of non-original spare parts.
Chap. 1
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Chap. 1
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CHAPTER 2 – Safety information
CHAPTER
2 Safety information
Chap. 2
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INDEX
2 Safety information ....................................................................................................... 1
2.1 Qualification of personnel .......................................................................................................................4
2.2 General safety rules .................................................................................................................................5
2.3 Use of Personl protective equipment (PPE) ..........................................................................................7
2.3.1 Minimum equipment ................................................................................................................................... 8
2.4 Safety and warning sings ........................................................................................................................9
2.4.1 Description of hazard images ..................................................................................................................... 9
2.4.2 Description of prohibition images ............................................................................................................. 13
2.4.3 Description of obligation symbols ............................................................................................................. 14
2.4.4 Description of miscellaneous and customised symbols............................................................................ 14
2.4.5 Location of information and warnings on the machine ............................................................................. 15
2.5 Envisaged use .........................................................................................................................................16
2.6 Reasonably foreseeable incorrect use .................................................................................................17
2.7 Information on the work environment ..................................................................................................18
2.7.1 Illumination and aeration .......................................................................................................................... 18
2.7.2 Dust removal system ................................................................................................................................ 18
2.7.3 Vibrations ................................................................................................................................................. 18
2.7.4 Electromagnetic emissions.......................................................................................................................18
2.7.5 Noise hazards typical of the wood industry .............................................................................................. 19
2.8 Safety devices .........................................................................................................................................20
2.8.1 Safety device checks................................................................................................................................ 24
2.8.1.1 Emergency pushbutton check ..............................................................................................24
2.8.1.2 Fixed and removable guard checks ...................................................................................... 24
2.8.1.3 PADLOCK STATION, clamps, padlock checks .................................................................... 25
2.8.1.4 Warning lights and horn check ............................................................................................. 25
2.8.1.5 Key management check .......................................................................................................25
2.9 Machine areas and workstations ..........................................................................................................26
2.9.1 Identification of work areas.......................................................................................................................27
2.9.2 Responsibilities of the operator in charge of running the machine ........................................................... 27
2.9.3 Responsibilities of the operator in charge of loading/unloading the machine ........................................... 27
2.9.4 Warnings regarding conduct inside the all-around enclosure ................................................................... 28
2.10 Machine operations/functions ...............................................................................................................28
2.11 Safety regulations for spindle use and maintenance .........................................................................31
2.12 Safety regulations for use and maintenance of mechanical components .......................................31
2.13 Safety regulations for programming.....................................................................................................32
2.14 Safety regulations for electrical maintenance .....................................................................................32
2.15 Safety regulations for pneumatic maintenance...................................................................................34
2.16 Residual risks..........................................................................................................................................34
2.16.1 Residual risks present during any stage...................................................................................................35
2.16.1.1 Passing through or stationing near dangerous areas – (Risk ID: 00.01) .............................. 35
2.16.2 Residual risks during normal operation .................................................................................................... 36
2.16.2.1 Normal operation – (Risk ID: 04.06) ..................................................................................... 36
2.16.2.2 Normal operation – (Risk ID: 04.07) ..................................................................................... 37
2.16.3 Residual risks during assembly/disassembly ........................................................................................... 38
2.16.3.1 Assembly/disassembly– (Risk ID: 06.01) ............................................................................. 38
2.16.3.2 Assembly/disassembly– (Risk ID: 06.03) ............................................................................. 39
2.16.4 Residual risks during handling and transportation .................................................................................... 40
2.16.4.1 Handling and transportation– (Risk ID: 07.01) ...................................................................... 40
2.16.5 Residual risks during various activities – inspection, cleaning, etc. .......................................................... 41
2.16.5.1 Various activities – inspection, cleaning, etc. – (Risk ID: 08.03) ........................................... 41
2.16.6 Residual risks during work on the electrical system ................................................................................. 42
2.16.6.1 Work on the electrical system – (Risk ID: 09.01) .................................................................. 42
2.16.6.2 Work on the electrical system – (Risk ID: 09.02) .................................................................. 43
2.16.7 Rischi residui presenti durante gli interventi di lubrificazione/ingrassaggio .............................................. 44
2.16.7.1 Lubrication/greasing – (Risk ID: 11.01) ................................................................................ 44
2.16.8 Residual risks during SINGLE PITCH loading/unloading (work cycle) ..................................................... 45
2.16.8.1 SINGLE PITCH loading/unloading (work cycle) – (Risk ID: 12.01) ....................................... 45
2.16.8.2 SINGLE PITCH loading/unloading (work cycle) – (Risk ID: 12.02) ....................................... 46
2.16.9 Residual risks existing in TANDEM processing cycle .............................................................................. 47
Chap. 2
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2.16.9.1 TANDEM processing cycle - (Risk ID: 13.01) ....................................................................... 47
2.16.10 Residual risks during HOLD-TO-RUN movements (portable control) ...................................................... 48
2.16.10.1 HOLD-TO-RUN movements (portable control) – (Risk ID: 15.01) ........................................ 48
2.16.11 Residual risks during height work ............................................................................................................. 49
2.16.11.1 Height work – (Risk ID: 16.01) .............................................................................................. 49
2.16.12 Residual risks during adjustments with laser devices .............................................................................. 50
2.16.12.1 Adjustments with laser devices – (Risk ID: 17.01) ................................................................ 50
2.16.13 Residual risks present during safeguarding work ..................................................................................... 51
2.16.13.1 Safeguarding work– (Risk ID: 18.01) ................................................................................... 51
2.16.14 Residual risks during interventions of telephone support and remote assistance .................................... 52
2.16.14.1 Telephone support and remote assistance interventions - (Risk ID: 19.01) ......................... 52
Chap. 2
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2.1 Qualification of personnel
This manual provides instructions on use and maintenance, lists the hazards and residual risks of the
machine but does not take into account the risks of the work environment and the specific work
modalities of the company using the machine.
As to the choice of the personnel responsible for operating the machine, it is up to the
employer to make sure that the duties assigned to workers are compatible with the
qualification and level of information and training required. It is indispensable that
qualified personnel such as operators, maintenance personnel and technicians, for
definitions see chapter 00, is exclusively made up of Expert Persons (EXP), and
Informed Persons (INFP) and not Common Persons (COMP).
INFORMATION!
Remember that it is up to the employer to inform and train the personnel
who is going to run the machine; this must be done on the basis of
available knowledge, information and instructions, before working activities
are assigned to workers.
The instructions of use and maintenance provided in this manual are not addressed to
Common Persons (COMP), who are not authorized to run the machine. However,
information on the safety of these persons is provided in this manual to facilitate the
employer to fulfil his duty of instruction and supervision.
INFORMATION!
Remember that instruction and supervision of common persons is up to the
employer.
Chap. 2
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2.2 General safety rules
A series of general rules for correct machine use are provided here following; these rules must be
integrated with the specific operating procedures.
It is up to the purchaser:
• to conduct a risk evaluation of the machine concerning the characteristics of the

installation environment and those of the company working modalities, assess and
understand the residual risks included in the manual in order to take the necessary
safety measures (Personl protective devices, working procedures etc.).
• Choose the suitable personnel for the use and maintenance of the machine and
train it.
• Define safe working processes and authorisation to working methods.
• Choose and equip personnel with suitable Personl protective equipment (PPE) for
the tasks to carry out.
• Check that personnel is mentally and physically fit to perform the tasks assigned.
The user actively participates in maintaining a high level of machine safety in the
long term. Please consider the following aspects concerning one’s responsibility
for use:
• Before starting any operation, read the instruction manual and abide by the safety
operational rules.
• Comply with the warnings located next to the dangerous areas.
• Use suitable clothing for the tasks to perform; avoid clothing with flapping parts and
do not use any hooking accessories to avoid entanglement and dragging.
• Always use Personl protective equipment (PPE) such as safety boots, gloves,
googles etc., if necessary, in accordance with the specific instructions of the
manual and company standards.
• Before performing any operation, take off watches, bracelets, rings, chains and pull
up your long hair or put on a cap.
• If there are considerable noise producing sources (over 80 decibel) always use
suitable ear protective devices (earmuffs, earplugs).
• Take on ergonomically correct positions to avoid strains or excessive tiredness
while performing these tasks.
• Make sure that there are no production residues or superfluous objects in the
working area or on the machine.
• Check the efficiency of all machine protections and safety devices every day and
before use; do not operate in case of malfunction; before using the machine restore
effective operation.
• Do not run the machine if protections have been removed.
• Do not circumvent the guards and safety devices voluntarily.
• Keep the characteristics of the machine and avoid making any modifications,
altering the function of the machine or tampering with protections or safety devices.
• Do not use the machine if there are operational malfunctions, defects, faults or
damage.
Chap. 2
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Maintenance personnel is required to:
• Implement a correct machine maintenance timetable.

• Check the state of the machine on a daily basis and immediately replace parts that
are worn or damaged.
• Do not perform maintenance or lubrication operations while the machine is moving.
• Perform all the operations foreseen for the machine to be safe.
• Use appropriate tools to repair the machine.
• Remove all tools used for maintenance from the work area.
• Restore all protections and safety devices that have been removed and check that
they function correctly.
Chap. 2
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2.3 Use of Personl protective equipment (PPE)
If the use of Personl protective equipment (PPE) is required according to the manual or signs/warnings
on the machine, remember that the choice of the most suitable type for the level of protection required is
up to the employer.
Personl protective equipment is defined by Directives 89/686/EEC and 89/656/EEC. In Italy reference
must also be made to Ministerial Decree No. 277/91, which has transposed into national law Council
directives 80/1107/EEC, 82/605/EEC, 73/477/EEC, 86/188/EEC and 88/642/EEC. The use of PPE is
indicated in the manual and on the machine with the symbols listed below:
Symbol Explanation
You are obliged to use protective clothing.
You are obliged to use PVC protective clothing.
You are obliged to use safety boots.
You are obliged to use protective gloves against general mechanical

risks.
You are obliged to use protective gloves against heat or fire related
risks.
You are obliged to use protective gloves against acides and corrosive
agents.
You are obliged to use protective gloves against chemical risks

(arising from lubricants).
You are obliged to use a safety helmet.
You are obliged to use safety goggles with side shields.
Chap. 2
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Symbol Explanation
You are obliged to use a shield protector.
You are obliged to use a respiratory facial mask (facemask for

covering the nose and nostrils).
You are obliged to use hearing protection devices (earplugs or

earmuffs).
You are obliged to use a safety belt for work at height.
2.3.1 Minimum equipment
The minimum workers’ Personl protective equipment (PPE) the employer is required to provide
comprises the following devices:
Symbol Explanation
You are obliged to wear safety clothing.
You are obliged to wear safety shoes.
You are obliged to wear safety gloves against general mechanical

risks.
You are obliged to wear hearing protection or earmuffs.
It is indispensable as a minimum requirement that the operator uses the Personl protective equipment
(PPE) mentioned above during all stages of machining of the machine.
Therefore, reference will be made to specific PPE as operators are considered to be equipped with the
devices mentioned above.
Chap. 2
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2.4 Safety and warning sings
2.4.1 Description of hazard images
DANGER IMAGES 1 of 4
SYMBOL DESCRIPTION OF HAZARD INDICATIONS/WARNINGS
If manual equipment is used, take care to
prevent cuts and shears. Follow the safety
Cutting, shearing
provisions and wear the appropriate PPE
(safety gloves against general risks).
Keep a safe distance from the indicated
zones to prevent guillotining or excision
Guillotining, excision hazards due to the movement of machine
parts or to the presence of sharp parts.
Follow the safety provisions.
zones to prevent snagging and dragging
Snagging and dragging hazards with the product or moving belts
and consequent dragging. Follow the
safety provisions.
Keep a safe distance from the areas
indicated so as to avoid dangers of
Dragging
dragging between rollers and rotating
components. Follow the safety provisions.
zones to prevent snagging and dragging
Snagging and dragging
with moving members or mechanical
components. Follow the safety provisions.
zones to prevent limb crushing. Do not
insert your hands into the sliding guides of
the machine units to prevent hazards due
Crushing of upper limbs
to the movement of the devices. Watch out
for all movements of the unit where the
image is located. Follow the safety
provisions.
Chap. 2
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zones to prevent lower limb crushing.
Crushing of lower limbs Watch out for all movements of the unit
where the image is located. Follow the
safety provisions.
Be careful near protruding or sharp
Impact machine parts. Follow the safety
provisions.
Be careful near protruding or sharp

Shock hazard (head or parts of the
machine parts and any hindrances. Follow
body) or snagging
the safety provisions.
Watch out for holes in the floor and for any

Falling in openings/hatches
ports or trap doors.
Watch out for objects or slippery
substances on the floor. Immediately
Slipping and falls
remove the objects and clean the floor from
substances.
Watch out for foreign matter laying on the
Tripping and falls floor that could cause tripping. Immediately
remove the obstacles.
In case of overhead work. Comply with the
Danger of falling from above safety dispositions and adopt the
appropriate PPE (safety belt).
Danger of falling due to height Watch out for any differences in the height
differences of different machine zones.
Be careful near the indicated zones.

Maintain a safety distance in order to avoid
dangers stemming from direct or indirect
Dangers of an electrical nature contact with parts or equipment with
voltage. Follow the safety provisions and,
in case of operations, wear the appropriate
PPE (safety gloves against electrical risks).
Be careful near the indicated zones.
Maintain a safety distance to prevent burns
caused by high temperatures. Follow the
Heat-related hazards
safety provisions and wear the appropriate
PPE (safety gloves against heat and fire-
related hazards).
Chap. 2
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Follow the safety provisions and adopt the
Hazards generated by noise for
appropriate PPE (ear safety devices or
values above 80 Db
soundproof headsets).
Corrosive agents Corrosive agents
Irritating agents Irritating agents
Flammable agents Flammable agents
Machine with automatic start-up Machine with automatic start-up
Radio-controlled components Radio-controlled components
Pay attention to the presence of residual

energy in all or part of the circuit. Always
disconnect the electricity before performing
maintenance work. Use the charts to
Residual electrical energy disconnect parts of the installation when
necessary. Pay particular attention to the
orange-coloured circuits which remain
under voltage even after the disconnection
of the electricity.
Chap. 2
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Be careful near the indicated zones. Keep a safe
distance to prevent the injection of fluids under
Injection of pressurised fluids pressure (pneumatic or hydraulic system). Follow
the safety provisions and wear the appropriate PPE
(safety screen).
Pay attention to the intense magnetic fields near
the pictogram. Persons wearing pacemakers must
Intense magnetic fields
maintain a safety distance from the machine or
parts of it when it is dismantled for maintenance.
Check that there are no potentially falling objects or
cables that could become entangled. Do not stand
Suspended loads or move during the load lifting and handling steps.
Follow the safety provisions and wear the
appropriate PPE (safety helmet).
General hazard
(the image is completed with the Adopt the precautions indicated in the warning text.
hazard description)
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2.4.2 Description of prohibition images
PROHIBITION IMAGES 1 of 1
SYMBOL DESCRIPTION INDICATIONS
No access to unauthorised personnel.

Access prohibited
It is forbidden to work without guards or

protection with exposed chains, gears or
moving components. Install any safety
Prohibition to remove the guards
devices and guards removed during
maintenance before starting the machine.
It is forbidden to perform repair operations
Prohibition to fix or adjust moving and/or adjustments to the machine, or
parts components, when it is moving. Follow the
safety provisions.
No water should be used for extinguishing
fires due to the presence of live
Prohibition to use water to components. Use powder extinguishers or
extinguish fires similar devices for the extinguishing
operations in the event of a fire. Follow the
safety provisions.
Do not step onto the machine or machine
Prohibition to step onto the
parts that are not designed to bear the
machine or machine parts
weight of persons.
Prohibition to climb onto the

Do not climb onto the machine structure or
machine structure or safety
safety guards.
guards.
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2.4.3 Description of obligation symbols
OBLIGATION IMAGES 1 of 1
SYMBOL DESCRIPTION INDICATIONS
It is mandatory to disconnect and isolate
Obligation of disconnection and the sources of energy before starting
isolation of the sources of energy. maintenance and adjustments on the
machine.
It is mandatory to refer to the instructions
(User’s manual and Maintenance, wiring
Use instructions
diagrams, etc.) provided with the machine,
before operating it.
It is mandatory to use Personl locks to
Use of padlocks for the blocking of
block the electrical system, pneumatic
the supply or access to the
supplies etc. or to access the machine and
machine
avoid untimely start-ups during works.
Using Personl protective Please refer to the paragraph “2.4 Use of

-
equipment (PPE) Personl protective equipment (PPE).
2.4.4 Description of miscellaneous and customised symbols
MISCELLANEOUS AND CUSTOM IMAGES 1 of 1

SYMBOL MEANING
Indication of the machine or its
component centre of gravity. This
Machine barycentre
indication is essential to arrange proper
machine or component lifting.
Indication of the machine lifting point.
This indication is essential for proper
Lifting point
machine or component lifting and
transport.
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2.4.5 Location of information and warnings on the machine
Ref. SYMBOL INFORMATION / WARNING LOCATION

AP01 Keep at a safe distance in order to Electrical boards, control
avoid hazards deriving from direct or panels
indirect contact with life parts or
instruments. Abide by safety rules and
Electrical hazards use appropriate Personal protective
equipment (PPE) (safety gloves against
electrical hazards).
AP02 Beware of sharp surfaces that may cut Located near the head.
or shear. Use appropriate Personal
protective equipment (PPE) (cut-proof
gloves).
Cutting, shearing
AP05 This symbol may be accompanied by Located near the laser
the following warning: regulation devices.
CLASS 2 LASER
WARNING: DO NOT STAND NEAR
THE LASER BEAM.
Pay attention and never look directly

into the laser beam.
AP06 Take heed of moving parts that are Located on the external
protected by safety measures (fixed and safety guards of the piece
removable guards) but may be reached loading/unloading area.
in case of improper conduct on behalf of
the operator authorized to run the
machine.
AD01 NO ACCESS for unauthorized Interlocking gates for
personnel. access to the machine
and electrical board.
Do not enter
AO02 IT IS MANDATORY to use the specified Located near the hoisting
hoisting points. points.
Hoisting point
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2.5 Envisaged use
Envisaged use means use of the machine in conformity with the information provided in the user
instructions.
The machine may be used only by professional operators who are trained and informed as to the
contents of this instructions manual.
Operators designated to running the machine are responsible for preparing the machine for operation,
starting up the machine and checking and adjusting the work parameters. All operations must be carried
out in accordance with the commands and work procedures described in the instruction manual.
The machine is designed to machine pieces made of wood or other similar materials, the characteristics
of which are defined in the technical data.
The machine is provided with 2 work stations, one in front of the control panel and another in front of the
loaders, where the operator may stand during the work cycle.
The machine may be used by only one operator at a time; simultaneous use by two or more operators is
forbidden.
Recipe settings and parameters are set using the HMI device installed on the electrical control panel.
Access to hazard areas for any task required for machine operation are limited by safety requirement
conditions; access to these areas must be carried out in conformity with the instructions provided in this
manual and in all annexed documents.
The machine is designed and manufactured to mill, drill and cut woody materials, materials deriving from
wood or other similar materials (1). The machine may not be used to process other kinds of materials;
uses different from that envisaged may damage the machine and constitute a hazard for operators.
To avoid possible, improper use, we recommend taking into consideration the consistency of the
material and rapport it to the spindle motor being used. Furthermore, do not use the machine to process
pieces that do not fit into the maximum work strokes specified in the section “Technical and ambient
data”.
NOTE (1): similar materials: materials with machining parameters for milling, drilling and cutting that are
comparable to the machining parameters for woody materials (for example: ureic resin, PVC, ...)
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2.6 Reasonably foreseeable incorrect use
Reasonably foreseeable incorrect use means use of the machine in a manner that differs from that
specified in the user instructions but that may derive from easily foreseeable human conduct.
The experience of the manufacturer, PAOLINO BACCI s.r.l. permits signaling out the following examples
of incorrect use machine use:
A) INSTALLATION
The following cases are considered incorrect use:
• Installing the machine in environments where, during normal work activities the atmosphere is or
may become explosive for short or long periods of time (classification as per the 1999/92/EC
ATEX Directive).
• Installing the machine outdoors or in environments with characteristics that are not conformant to
the ambient technical data specified in the instruction manual.
• Installing the machine without abiding by the instructions provided by the manufacturer PAOLINO
BACCI s.r.l.
B) USE
The following cases are considered incorrect uses:
• Use on behalf of operators who are not of legal working age in accordance with the laws currently
in force in the country of use.
• Use on behalf of operators who have not been trained, formed and informed in advance as
regards all residual risks and trained regarding safety issues.
• Using the machine without the proper Personal protective equipment (PPE), as required by the
instructions and by the laws in force in the country of use.
• By-passing machine safety device even temporarily.
• Using the machine even if it shows signs or malfunction or is partially malfunctioning
• Failure to respect the technical data regarding machining limits (materials, speed, etc.).
• Simultaneous use of the machine by two or more operators who may reciprocally endanger one
another or create hazards for exposed persons.
• Machine start-up by the sole operator designated for use, without checking that there are no
exposed persons in the machine danger areas before acting on the machine controls.
C) PERSONNEL TRAINING AND INFORMATION

• Running the machine without having read and comprehended the instructions provided by the
manufacturer PAOLINO BACCI s.r.l
• Carryout out operations regarding which the manufacturer PAOLINO BACCI s.r.l. has not
provided instructions or information.
• Carrying out operations that are difficult to interpret based on the instructions provided by the
manufacturer PAOLINO BACCI s.r.l.
• Carrying out operations in a manner different from that described in the instructions.
• Carrying out operations that are expressly prohibited in the instructions.
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D) ALTERATIONS
• Altering the machine in any way that alters the envisaged use of the machine.
2.7 Information on the work environment
The machine has been constructed to operate in closed, well ventilated environments that are full of
light. Temperature and humidity rates in the work environment must be within the limits mentioned in the
specific technical data attached to this manual.
Environmental conditions other than the ones indicated in this manual may seriously damage the
machine, particularly electronic devices.
Positioning the machine in unsuitable environments that do not meet the established requirements shall
lead the expiry of the warranty for the parts to replace.
If the machine does not work, it must be stored taking all the necessary precautions as established in
this manual. Temperature and humidity rates in the place where the machine will be stored must be
within the limits mentioned in the specific technical data attached to this manual.
2.7.1 Illumination and aeration

The place where the machine is installed must be adequately illuminated for the operations to be
performed; shady areas, disturbing glare and stroboscopic effects must be avoided.
Abide by the current standards on illumination of work environments. Please note that the lack of
adequante lighting could pose risks for the persons exposed.
The machine must run in a properly aerated environment.
2.7.2 Dust removal system

The machine is not supplied with a dust removal system. For proper and safe machine use, the machine
must be connected to a dust removal system that is conformant to the specifications provided in ANNEX
B TECHNICAL DRAWINGS AND GENERAL INFORMATION.
2.7.3 Vibrations
Mechanical vibrations, if transmitted to the hand-arm system and/or to the whole body: pose risks for the
health and safety of operators as evaluated on the basis of the European Directive 2002/44/EC.
2.7.4 Electromagnetic emissions

The machine contains electronic components in line with the Electromagnetic Compatibility standards,
that are subject to transmitted or irradiated emissions.
The emission values are conformant to regulatory requirements thanks to the use of components that
comply with the Electromagnetic Compatibility Standards, appropriate wiring and connections and the
installations of filters as required. Hence, the machine is conformant to European Directive 89/336/EC on
Electromagnetic Compatibility (EMC).
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2.7.5 Noise hazards typical of the wood industry

The wood processing industry is traditionally characterized by processes that create high noise exposure
levels, due to a series of concomitant factors, such as the use of tools that have an elevated noise force
concentrated in work environments that are often tight. The work logistics typical of wood-working shops,
where the interchangeability of the tasks and the variable equipment use times are standard working
conditions, do not permit calculating worker exposure to noise in a precise manner.
By way of example, the noise emission values for the machine during a work cycle are provided below:
material: beech elements, rough worked, average thickness 25mm

machining: milling and tenoning
tools: HM hard metal milling cutter, 10mm diameter
HM hard metal milling cutter, 18mm diameter
Milling cutter for tenoning
Rough-milling cutter; 30mm diameter
Measured without the use of a dust removal system.
NOISE EMISSION VALUE

Background noise 68.5 dB(A)
Empty run 74.6 dB(A)
Work run 78.8 dB (A)
During machining, especially when the tool enters the materials, noise peaks up to 109.8 dB (A) were
reached.
The above-mentioned noise values are emission values and not necessarily safe working levels.
While there is a correlation between emission levels and exposure levels, it may not be used reliably to
determine whether or not additional precautions are required.
Factors affecting the actual worker exposure level include:
• Duration of exposure,
• Environment conditions,
• Other noise sources, such as for example the number of machines are other machining work in
the vicinity.
Furthermore, permitted exposure levels may vary from one country to another.
The information provided herein is nevertheless sufficient to allow machine users to better assess risks
and hazards.
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2.8 Safety devices
This section contains information regarding the safety devices adopted to eliminate or reduce machine
hazards.
When a safety device does not fully eliminate a hazard and a reduced risk remains, this risk is described
in the manual as a residual risk.
The safety devices that have been installed must be checked and kept efficient during the machine’s
entire service life.
• Carry out the periodic checks described in this manual.

• Removing or by-passing the safety devices (e.g. guards, photocell barriers, etc.), even
temporarily, is forbidden.
DEVICE TYPE / FUCNTION PHOTO / NOTES

M01 EMERGENCY STOP The emergency stop pushbuttons are located
Emergency stop device located on every on the machine as follows:
control panel, to be activated in the event of
danger for the exposed person. • On the main pushbutton panel.
• On the loader pushbutton panel.
• On the portable pushbutton panel.
Pressing the emergency stop immediately

stops the machine and cuts off power to
dangerous machine components.
M02 LOCK-OUT/TAG-OUT Before carrying out any maintenance on the
All power sources may be blocked in the OFF machine, power sources must be locked and
position using clamps and padlocks. tagged out using the appropriate padlocks
and clamps.
• Compressed air valve
M03 SIGNAL COLUMN Every time the machine is started up, the
Signals machine conditions using warning warning lights turn on and the horn sounds,
lights and horns. so as to warn everybody present in the work
area of imminent machine start-up.
If necessary, press the nearest emergency

stop button to interrupt machine start-up.
M04 FIXED GUARD (ALL-AROUND The all-around enclosure consists in safety
ENCLOSURE) panels that protect the entire machine. The
All-around enclosure made of sheet metal and enclosure may be accessed through the
transparent material (e.g. polycarbonate), doors, which are fitted with interlocking
strong enough to resist flying utensils. device that block the panels.
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M05 REMOVABLE GUARD Each access door is fitted with an
Access door fitted with interlocking device and interlocking device and guard block. During
guard block. regular machine operation, the door is closed
and blocked. To access inside the enclosure,
stop the machine and wait for the lock to
release. In case of power shortage, the door
remain blocked. In this case, the doors may
be unlocked mechanically using the specific
wrench installed near the interlocking device.
M06 COMBINATION OF REMOVABLE GUARDS The doors and/or movable guards have the
A system that provides access to the piece purpose of protecting the operator against
loading area, made up of an assembly of the movement of the machining head, during
removable guards. the loading/unloading of the pieces.
An example application is a single guard that NOTE: In case of guards for machines with
stops all dangerous movements of the Y1-Y2 axes table, the ejection of tool
machine, when it is opened. Only when the fragments is reduced to a minimum, at least
guard is closed, the machine can perform the along the direction of two horizontal axes
operating cycles (for use in single-table (ref. EN 848-3:2007+A2:2009, section
machines with Y axis or X-Y axes). 5.3.7.1.2.3.1).
.
A further example application is a protection
made up of 4 guards named A, B, C, D (for
use in machines with Y1-Y2 axes table). The
opening/closing pattern is such that the
coordinated opening/closing of the guards
allows access to loading/unloading areas, in
which dangerous movements are safely
blocked, but does not allow access to other
areas where the operating cycle continues to
be performed. An example of such operating
pattern is the following:
LOADING:
(C)… OPEN / (A)…CLOSED
(D)… OPEN / (B)…CLOSED
UNLOADING:
(B)… OPEN / (D)…CLOSED
(A)… OPEN / (C)…CLOSED
Note: Each guard is fitted with an interlocking

device and guard block.
M08 FIXED GUARD The guards are fitted on the internal machine
Guards positioned to protect internal machine parts inside the all-around enclosure and
organs. protect operators carrying out controlled
movement of the axes while standing inside
the all-around enclosure.
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M09 HOLD-TO-RUN Only expert and authorised personnel may
Hold-to-run pushbuttons located on the use the portable pushbutton panel.
portable pushbutton panel.
This pushbutton panel is used to manually
control the movement of each axis, one at a
time, while standing inside the all-around
enclosure.
The axes move constantly and at reduced

speed for as long as the button is pressed.
When the button is released, the movement
stops. The pushbutton panel is also fitted
with a consent command that must be kept
pressed to enable all other comands.
M10 PRESSURE LIMITATION The pressure chanige is managed
Limitation of the closing pressure on the piece automatically by the machine. During piece
blocking devices during piece loading/unloading, the clamping pressure is
loading/unloading. controlled by a safety pressure gauge. Clamp
opening and closing is controlled by a foot-
pedal control, protected against involuntary
operation.
M11 FIXED GUARD The protection must be exclusively removed
Central protection located between the piece by the maintenance technician for performing
support devices (axes Y1 and Y2). machine setup, for tandem processing.
The tandem processing requires a machine

setup by the maintenance technician, who
removes the central guard located between
the two axes Y1 and Y2, and enables the
tandem processing in the software, which
allows synchronous advancing of axis Y1
and Y2. At the end of the tandem processing,
the maintenance technician must perform the
setup for SINGLE-STEP, loading/unloading
processing. To do this, it is mandatory to
reassemble the central guard and disable the
tandem processing in the software.
M12 SAFETY EDGE In case the safety edge is bumped during
The doors of the movable guard combination closing, the closing operation is stopped and
(PROTECTION MEASURE M06) are the door is opened.
equipped with a safety edge, to prevent
crushing of the person during automatic
closing.
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M13 DUST EXTRACTION (PREPARATION) Connect the machine to a vacuum system
The machine is ready to be connected to a whose characteristics are described in the
dust extraction device (not supplied). technical data. The vacuum system
characteristics should ensure a HIGH
effectiveness degree and GOOD availability,
in order to reduce the dust concentration in
both the surroundings and the extraction
duct, and be capable of stopping the
processing in case of failure of the extraction
system, or the presence of backup extraction
systems.
The customer/end user is responsible for the

supplying and installation of the dust
extraction system.
QE01 LOCK-OUT/TAG-OUT Before carrying out any maintenance on the
All power sources may be blocked in the OFF machine, power sources must be locked and
position using clamps and padlocks. tagged out using the appropriate padlocks
and clamps.
• Electrical board switch
QE02 ELECTRICAL BOARD KEY During normal machine operation, the key to
Lock and key to access the electrical board. the electrical board must be removed. The
The key must be used only by expert and key must be kept by expert and qualified
qualified personnel. personnel, in compliance with the procedures
set forth in the workplace.
QE03 SAFETY GUARDS AGAINST DIRECT AND -
INDIRECT CONTACT
Creation/installation of containers and sheaths
capable of insulating live machine parts as
required.
Wiring of electrical equipment in compliance

with CEI EN 60204-1 standards.
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2.8.1 Safety device checks
NOTE: The checks described here below refer to the guards described in the preceding sections
of the manual.
2.8.1.1 Emergency pushbutton check
Once a year, check:
Test A): impede machine start-up

• Press the emergency pushbutton and check that it remains blocked.
• Check that the emergency light turns on.
• Check that when the emergency pushbutton is pressed the machine will not start up.
Test B): reset emergency pushbutton

• Turn the emergency pushbutton clockwise and check that it releases.
• Check that the machine will now start up.
NOTE: Both tests must be repeated for each emergency pushbutton on the machine.
2.8.1.2 Fixed and removable guard checks
Every time the machine is used, carry out the following checks:
• Visually check that the guards are in place before using the machine.
• For removable guards, check that the interlocking device is functioning properly.
Once a year, check:
• That there is no damage due to impacts or improper use.

• That the supports and anchoring screws are tight.
Check that the guards are assembled properly and functional after every maintenance intervention.
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2.8.1.3 PADLOCK STATION, clamps, padlock checks
At each use, carry out the following check:
• Check that the padlocks and clamps to lock off and tag out energy supplies are always on hand.
NOTE: padlocks and clamps are not supplied by the machine manufacturer Paolino Bacci S.r.l ,
and must be provided to operating personnel by the employer.
2.8.1.4 Warning lights and horn check
At each use, carry out the following checks:
• Regularly check that the lights and horns are working properly.
2.8.1.5 Key management check

The employer is required to set up a key management procedure. The keys may be used only by skilled
and qualified personnel aware of machine risks.
Always check:
• That the keys are used only for the time required by the intervention. Once the intervention is
completed, they must be removed and stored by the designated person.
• The keys may be used only by authorized and qualified personnel, identified in a written
procedure.
• It is forbidden to duplicate the keys.
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2.9 Machine areas and workstations
The machine is designed and manufactured considering use by only one operator, whose task it is to
supply the machine for production and remove the machined product, as well as operate the manual
controls, only after having verified that there are no exposed persons in the danger areas.
INFORMATION!
During normal machine operation, operators may station in the areas specified here following.
INFORMATION!
The work area must always be free, and nothing must hinder the operator’s freedom of movement.
In case of an emergency, immediate access to the machine on behalf of designated personnel must be
ensured.
Pos. Zone Location Workstation / authorized personnel

Z01 Electrical Electrical boards, boxes, The outside of the electrical board may be
equipment machine boards with live parts. accessed by the operator only after the
Only skilled technical personnel machine power on/off and control knife
may work on electrical switch has been enabled (Identified as
equipment. Z04).
The inside of the electrical board may be

accessed for interventions on live and
sectioned parts only by skilled and
authorized personnel.
Z02 Material Area at the front of the machine This is the main workstation where the
loading/unloadin where the operator stations for operator stands during machine operation.
g zone material loading and unloading.
Z03 Inside the Area inside the machine where The area inside the machine may be
machine machining of the pieces loaded accessed by opening the access ports.
on the clamps is carried out by Access conditions are limited by the
the tooling head. machine safety logic.
Z04 Control panel Outside front part of the This is the workstation from which the
electrical board where the operator may control the machine and
machine controls and HMI program the work cycle using the special
software interface are located. HMI interface.
Z05 Portable Area inside the machine guards Standing inside the guards, keeping away
pushbutton from which the portable from moving parts, the operator may control
panel pushbutton panel controls may one axis at a time using the hold-to-run
be operated. function. Controls are operated using a
portable pushbutton panel that may be
brought inside the enclosure.
This internal area of the machine may be

accessed by opening the access ports.
Access conditions are limited by the
machine safety logic.
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2.9.1 Identification of work areas
The area around the main pushbutton panel and loading/unloading are the main operator
work areas from which the operator may enable commands, program work cycles and
check proper machine operation. For maintenance and to fit tools on the machine, the
operator must also access the safety enclosure.
2.9.2 Responsibilities of the operator in charge of running the machine
Before starting the work cycle, the operator in charge of running the machine must be
perfectly aware of the location and function of all the controls and of the machine
characteristics. The machine must be run only by operators who have been specifically
trained and have read the instructions contained in this manual thoroughly. Instructions,
warnings and general accident prevention regulations contained in this manual must be
followed scrupulously.
2.9.3 Responsibilities of the operator in charge of loading/unloading the machine
Before starting the work cycle, the operator in charge of loading/unloading the machine
must be perfectly aware of the location and function of all the controls and of the machine
characteristics. The machine must be run only by operators who have been specifically
trained. Loading and unloading operators must have read the instructions regarding piece
loading and unloading and the general safety instructions contained in this manual.
Instructions, warnings and general accident prevention regulations contained in this
manual must be followed scrupulously.
.
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2.9.4 Warnings regarding conduct inside the all-around enclosure
• Interventions inside the all-around enclosure must be carried out only by qualified
technicians. Before carrying out this type of interventions, place a “MAINTENANCE
UNDERWAY” sign on the machine.
• While working inside the all-around enclosure, open the doors and keep them open.
2.10 Machine operations/functions
The following machine operations and functions have been assessed for risks. Those operations and
functions that present risks are specified in the “residual risks” section of this manual.
Operation / Function Task N. Description Stage

Passing through or standing 00 Assessment of risks deriving from the Any
near dangerous areas possibility that common persons (not
trained and instructed regarding risks)
may be exposed to risk situations.
Starting the work cycle 01 Operation carried out by the operator Use
to start up the machine. The operation
is carried out using the electrical
control panel and standing at a
distance from the machine danger
areas (safety devices reset). From this
moment on, the machine is ready for
all operating modes.
Stopping the work cycle 02 Operation carried out by the operator Use
to stop the machine (working stop).
This operation is carried out using the
operator panel and standing at a
distance from the machine danger
areas.
Emergency stop 03 Operation carried out by the operator Use
to stop the machine in case of
imminent risk for persons. The
operation is carried out using the
operator panel or the emergency
pushbuttons located near the machine,
at a distance from machine danger
areas.
Normal operation 04 Machine status in which, after the Use
machine has been started up, it runs
with all the safety devices enabled.
Use of controls 05 Use of machine controls. Use
Assembly/disassembly 06 Operations carried out during Maintenance
installation or at the end of the life
cycle (dismantling and scrapping).
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Handling and transportation 07 Maintenance work carried out by Transport,
mechanical technicians and in part by installation and
the machine operator (simple cleaning assembly
and visual inspections).
Various activities - inspection, 08 Maintenance work carried out only by Maintenance
cleaning, etc. electrical and electronic technicians.
Work on the electrical circuit 09 Maintenance work carried out only by Maintenance
mechanical technicians.
Work on the pneumatic circuit 10 Maintenance work carried out only by Maintenance
Lubrication / greasing 11 Maintenance work carried out only by Use
SINGLE PIECE 12 Material loading/unloading with the Use
loading/unloading (work operator standing in front of the
cycle) machine, manually loading and
unloading the piece(s) on/from the
support devices located on the table.
Once the piece is placed, it is locked
by pressing the pedal button; then the
loading operation is confirmed, for the
machine to bring the piece in working
position (inside the machine, in the
machining heads area).
The closing of the clamps during the

stage when the operator interacts with
the support device, is performed at a
reduced pressure. The pressure is
then increased after confirmation of
loading end, by pressing the specific
button.
At the end of processing the piece is

automatically taken outside the
machine and the operator manually
removes it from the support devices;
then a new piece is loaded and
another processing cycle is started.
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TANDEM processing cycle 13 The processing occurs with the piece Use
supported by both the support devices
(Y1 and Y2 axes) that move
synchronously. The tandem processing
requires a machine setup by the
maintenance technician, who removes
the central guard located between the
two axes Y1 and Y2, and enables the
tandem processing in the software,
which allows synchronous advancing
of axis Y1 and Y2. At the end of the
tandem processing, the maintenance
technician must perform the setup for
SINGLE-STEP, loading/unloading
processing. To do this, it is mandatory
to reassemble the central guard and
disable the tandem processing in the
software.
The processing cycle occurs in the
manner described for the SINGLE-
STEP, loading/unloading processing
cycle.
Jam removal – Scrap removal 14 Operator interventions to remove Use
pieces that have become jammed
during machining.
HOLD-TO-RUN controls 15 Machine movements carried out only Maintenance
(portable pushbutton panel) by skilled and authorized personnel
using the portable pushbutton panel
inside the all-around enclosure.
Height work 16 Work on ladders and/or scaffolding. Maintenance
Adjustment work using laser 17 Adjustment work using laser devices. Maintenance
devices
Safety work 18 Work carried out to ensure the safety Use
of persons exposed to machine
hazards.
Telephone support and 19 Troubleshooting and repair operations Troubleshooting
remote assistance carried out through the telephone and repair
support service by the manufacturer.
The intervention may require the
connection of the machine control logic
to teleservice lines.
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2.11 Safety regulations for spindle use and maintenance
Before starting the spindles turning, it is essential to:
• Check that the tools have been fitted only after the spindle seat has been cleaned.
• Check that the tools are clamped tightly.
• Make sure that the number of programmed revolutions is less than the maximum number of
revolutions permitted for the tools fitted on the heads.
• Make sure that the size and weight of the tolls and the number of programmed revolutions is
compatible with the spindle power characteristics.
• Make sure that the direction of rotation is the proper direction of the tools fitted on the heads
during machining.
• If one spindle must turn in the opposite direction with respect to the standard rotation, check that
the safety ring-nut (or other appropriate safety devices) is present and tight.
• If there is an all-around enclosure or cabin, make sure that the doors are closed and that none is
standing inside the enclosure.
• Check the conditions of the tools and make sure that they are not chipped or deformed.
• Make sure that the tools, spacers and tool holding shafts meet the specifications contained in the
machine instructions.
Before bringing the spindle to the programmed revolving speed, start the spindle turning slowly and
check (by listening to the noise) that the tools are balanced and do not vibrate excessively.
Before stopping spindle rotation during machining, make sure that the tool is not in contact with the piece
and/or parts of the template.
2.12 Safety regulations for use and maintenance of mechanical

components
Do not remove the safety guards (panels and gates) except for ordinary and extraordinary maintenance.
Never start-up the machine when the guards are not in place.
Do not touch moving or rotating parts.
Do not carry out maintenance or cleaning while the machine is running.
Do not enable any machine movement if someone is inside the enclosure.
Do not enable blocking devices if someone is inside the enclosure.
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2.13 Safety regulations for programming
Before starting any program, including automatic homing, we recommend making sure that the portable
pad is enabled in order to be able to reduce speed and, if necessary, stop machine movements.
When running a program for the first time, disable spindle start-up (following the procedure described in
the relative section of the manual) and proceed at reduced speed using the potentiometer on the
keypad.
Respect the technological parameters for tools and machining, especially as regards machining speed
and the number of spindle revolutions.
Do not use the potentiometer to reduce or control speed during normal production.
2.14 Safety regulations for electrical maintenance
Knowledge of first-aid procedures for electrical accidents is required. Before starting maintenance on
electrical circuits, the person in charge of the work must check that all safety regulations have been
respected. Comply with current national laws and regulations regarding work on electrical systems.
• All work must be carried out using only suitable and isolated tools.
• Respect safety signs! Do not remove the safety signs.
• Before starting work, adopt the precautions described below.
Follow this procedure:

STEP OPERATION RESULT
Remove voltage. When electrical power has been cut off, the
1 Turn the main switch to "0". machine is not live. The connection area up
to the main switch is still powered.
Wait a few seconds before opening the The condensator in the inverter loses charge
2 electrical cabinet. a few seconds after the main switch has
been turned off.
Adopt all safety measures required to
3
avoid start-up. Padlock the main switch.
Check that the electrical power has been
4
disconnected.
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• Do not insert or pull out plugs when the power is on.

• Do not disconnect the yellow/green (earthing) safety wire or use it for other purposes. At the end
of every maintenance intervention, check that it is functioning properly!
• Use only original spare parts. P. Bacci S.r.l. is not liable for damage or malfunctions in case of the
use of non-original electrical components.
• If components are replaced, check that the proper settings of the safety and control devices of
the new components.
• Do not disable, move or modify the safety and control devices required for machine safety without
prior consent. These devices may be used only for the purpose envisaged! Do not modify circuits,
components, etc. nor the software!
• Upon completion of any maintenance and repair work, tighten all the screws on electrical
connections in the area involved in maintenance.
• Upon completion of any maintenance or repair work, check the safety devices.
• Keep live electrical components dry and do not expose them to humidity.
• Before cleaning electrical tools, cut-off the power!
• Keep the doors of the main cabinet and the various electrical boxes closed!
• In case of fire, cut off electrical power to all electrical system components that are dangerous or
exposed to risk, provided that cutting off the power does not engender other risks. Use only
appropriate fire-extinguishers.
• Do not use compressed air to clean the machine or the electrical cabinet; use only industrial
vacuums.
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2.15 Safety regulations for pneumatic maintenance
1 1
2
• Maintenance may be carried out only by qualified technicians. Before starting any type of
maintenance, place a “MAINTENANCE UNDERWAY” warning sign on the machine, stop the
machine and cut-off all electrical and pneumatic sources. For this purpose, close the main
pneumatic supply valve (1), then turn off the main switch (2) and adopt all the measures required
to avoid start-up.
• To carry out maintenance on the pneumatic system, first release the pressure using the
pneumatic EMERGENCY STOP switch (1) and releasing all residual compressed air.
• Use appropriate tools and equipment for proper disassembly and re-assembly.
• Use only appropriate hoisting equipment. Before hoisting the unit, check the weight, barycenter,
and location of the anchor points. Please consult the specific instructions contained in the
Installation chapter.
• Before starting the system, check for defects.
• Make sure that the machine safety devices are present and functioning. Do not remove safety
devices or other safety equipment. If safety devices must be dismantled, for example for
maintenance or repair work, they must be replaced immediately upon completion of the work and
tested for proper functioning.
• Follow current safety regulations when handling oils, greases and other chemical substances.
2.16 Residual risks
The machine is manufactured and protected so as to provide for maximum safety only when used in
compliance with the specifications for use. The machine is equipped with safety devices to safeguard
operating personnel.
Some risks cannot be fully eliminated. Personnel are therefore exposed to some residual risks. Such
risks are specified and described following, along with possible causes and the precautions to be taken
to avoid them.
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2.16.1 Residual risks present during any stage
2.16.1.1 Passing through or stationing near dangerous areas – (Risk ID: 00.01)
IDENTIFICATION RISK ASSESSMENT

Stage: Any Initial risk: HIGH
Person: Common person
Area: Z00 All areas RESIDUAL RISK: LOW
PLr (EN 13849): -

SIL (EN IEC 62061): -
ACCIDENT SCENARIO
Consequence: 1.0 Various mechanical hazards
Situation: Passing through or stationing near the dangerous machine areas during the various
stages of the life cycle (installation, use, maintenance, etc.)
Event: Contact with moving machine parts and the product being machined.
Contact with moving machine parts, suspended loads, eqiupment and/or equipment
used during assembly and maintenance.
Contact with toxic and noxious elements used during machine operation.
Risk of permanent damage to hearing apparatus due to high noise and prolonged
exposure to noise sources.
Body part: Entire body.
RESIDUAL RISK
Common persons who have not been instructed may be exposed to various risks deriving from both the
machine and the work environment. The employer must limit access to dangerous areas on behalf
common persons in specific company procedures.
LIMITATION MEASURES
Mechanical: -
Electrical: -
Informative: - unauthorised personnel may not enter the machine.
- Common persons who, for whatever reason, must pass through or station near
the machine must always be accompanied by personnel who have been trained
and informed regarding the risks, who must keep an eye on common persons.
Symbols: - Access denied to unauthorised personnel signs (WARNING AD01).
- Ground signs limiting and identifying dangerous areas.
- Internal company procedures.
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2.16.2 Residual risks during normal operation
2.16.2.1 Normal operation – (Risk ID: 04.06)

Stage: Use Initial risk: HIGH
Person: Operator
Area: Z03 Inside the machine RESIDUAL RISK: MEDIUM
PLr (EN 13849): -

SIL (EN IEC 62061): -
ACCIDENT SCENARIO
Consequence: 7.6 Fire
Situation: Accumulation of dust and machining residues (chips).
Event: Fire hazard deriving from contact between dust and machining residues with live
flames or parts of the electrical system.
RESIDUAL RISK
Fire hazard deriving from contact between dust and machining residues with live flames or parts of the
electrical system.
LIMITATION MEASURES
Mechanical: Arrange for connection to a centralized dust removal system (SAFETY MEASURE
M13)
Electrical: -
Informative: - Connect the machine to a vacuum system with a capacity equal to that specified
in the technical data.
- Periodically remove dust and machining residue from the machine frame, avoiding
accumulation.
- Do not use live flames and periodically check the insulation of all electrical
components near dust accumulations spots.
- The employer is required to include this assessment in the plant risk assessment
procedures procedure in order to implement appropriate ORGANISATIONAL
measures for risk reduction.
Symbols: -
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2.16.2.2 Normal operation – (Risk ID: 04.07)

Stage: Use Initial risk: MEDIUM
Person: Operator
Area: Z02 Material loading/unloading area RESIDUAL RISK: MEDIUM
PLr (EN 13849): -

SIL (EN IEC 62061): -
ACCIDENT SCENARIO
Consequence: 7.1 Respiratory difficulties, suffocation
7.2 Cancer
Situation: Dust emissions into the air
Event: Respiratory difficulties deriving from the presence of dust in the air cause by
material machining.
Body part: Breathing apparatus
RESIDUAL RISK
Respiratory difficulties deriving from the presence of dust in the air cause by material machining.
LIMITATION MEASURES
Mechanical: Arrange for connection to a centralised dust removal system (SAFETY MEASURE
M13)
Electrical: -
Informative: - Connect the machine to a vacuum system with a capacity equal to that specified
in the technical data.
Symbols: -
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2.16.3 Residual risks during assembly/disassembly
2.16.3.1 Assembly/disassembly– (Risk ID: 06.01)

Stage: Maintenance Initial risk: HIGH
Person: Specialised technician
Area: Z00 All areas RESIDUAL RISK: MEDIUM
PLr (EN 13849): -

SIL (EN IEC 62061): -
ACCIDENT SCENARIO
Consequence: 1.3 Crushing
1.4 Cutting or shearing
Situation: Working in machine assembly areas.
Event: Various risks (crushing, shearing) deriving from machine or machine parts
assembly.
1.3 CRUSHING:
- Under falling parts being handled
- Between machine parts being handled and surrounding structures (plant, other
machines).
- Between machine parts being handled and cables or straps used for hoisting.
1.4 CUTTING OR SHEARING:
machines).
Body part: Entire body, upper limbs, hands
RESIDUAL RISK
Various risks (crushing, shearing) deriving from machine or machine parts assembly.
Crushing:
- Between machine parts being handled and surrounding structures (plant, other machines).
Cutting or shearing:
LIMITATION MEASURES
Mechanical: -
Electrical: -
Informative: - This operation is reserved exclusively to expert personnel (EXP) with significant
know-how and experience such as to allow for proper assessment of the risks and
avoidance of the hazards engendered by the task.
- Mark off the work area and forbid access by unauthorised persons.
- Follow assembly instructions.
The employer is required to use only expert personnel (EXP) for assembly work.
Symbols: -
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2.16.3.2 Assembly/disassembly– (Risk ID: 06.03)

PLr (EN 13849): -

SIL (EN IEC 62061): -
ACCIDENT SCENARIO
Situation: Working in machine disassembly areas
Event: Various risks (crushing, shearing) deriving from machine or machine parts
disassembly.
1.3 CRUSHING:
machines).
machines).
RESIDUAL RISK
Various risks (crushing, shearing) deriving from machine or machine parts disassembly.
Crushing:
LIMITATION MEASURES
Mechanical: -
Electrical: -
The employer is required to use only expert personnel (EXP) for disassembly work.
Symbols: -
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2.16.4 Residual risks during handling and transportation
2.16.4.1 Handling and transportation– (Risk ID: 07.01)

Stage: Transportation, installation and assembly Initial risk: HIGH
PLr (EN 13849): -

SIL (EN IEC 62061): -
ACCIDENT SCENARIO
Situation: Working near machine parts being hoisted during handling and transportation
operations.
Event: Various risks (crushing, shearing) deriving from handling of machine or machine.
1.3 CRUSHING:
machines).
machines).
RESIDUAL RISK
Various risks (crushing, shearing) deriving from handling of machine or machine parts.
Crushing:
LIMITATION MEASURES
Mechanical: Anchor and hook-up points for hoisting equipment.
Electrical: -
The employer is required to use only expert personnel (EXP) for handling.
Symbols: Indication of hoisting points (WARNING AO2)
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2.16.5 Residual risks during various activities – inspection, cleaning, etc.
2.16.5.1 Various activities – inspection, cleaning, etc. – (Risk ID: 08.03)

Stage: Maintenance Initial risk: MEDIUM
Person: Operator
PLr (EN 13849):

SIL (EN IEC 62061):
ACCIDENT SCENARIO
Consequence: 7.9 poisoning
7.10 Sensitisation
Situation: Use of toxic and/or noxious substances for machine cleaning.
Event: Various risks (7.9 POISONING, 7.10 SENSITISATION) deriving from the type of
substance use to clean the machine, due to both skin contact or inhalation of
dangerous fumes (eg. accidental mixing of detergents).
RESIDUAL RISK
During machine cleaning, risks of POISONING and SENSITIZATION remain, resulting from the kind of
chemicals used for cleaning the machine, from contact with the skin and from inhalation of dangerous
fumes (i.e. accidental mixtures of detergents).
LIMITATION MEASURES
Mechanical: -
Electrical: -
Informative: Always use Personl protection equipment (PPE) suited to the type of product used
for cleaning.
Symbols: -
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2.16.6 Residual risks during work on the electrical system
2.16.6.1 Work on the electrical system – (Risk ID: 09.01)

Person: Maintenance personnel
Area: Z01 Electrical equipment RESIDUAL RISK: MEDIUM
PLr (EN 13849): -

SIL (EN IEC 62061): -
ACCIDENT SCENARIO
Consequence: 2.4 Electrocution
Situation: Maintenance on the electrical system (inspection, adjustment, substitutions).
Event: Risk of electrocution from direct and indirect contact with live parts.
RESIDUAL RISK
Risk of electrocutiion from direct and indirect contact with live parts.
LIMITATION MEASURES
Mechanical: - Create/install containers and sheaths capable of guarantying adequate insulation
of live parts (SAFETY MEASURE Q03).
- Wiring of electrical instruments in compliance with CEI EN 60204-1 standards
(SAFETY MEASURE Q03).
- Electrical cabinet doors may be opened only with a key entrusted to maintenance
personnel (SAFETY MEASURE Q02).
- The door to the electrical cabinet cannot be opened when the switch is in the ON
position.
Electrical: -
Informative: - Work on the electrical instruments, be they powered or not, may be carried out
only by expert personnel (EXP) and informed persons (INFP), as per the definition
provided for in CEI 11-27. CEI EN 60204-1 standards do not differ between work
carried out on electrical instruments that are not power and those that are live,
therefore not obligatorily requiring that the latter be carried out by Competent
Persons (COP) as per the definition provided for in CEI 11-27.
- Work on live equipment carried out inside the electrical board may be performed
only after having cut off power, having opened the board door, and having newly
powered the equipment by purposely turning the main switch to ON.
Symbols: - Electrocution warning sticker on boards and boxes containing live parts
(WARNING PE01)
- Do not enter prohibition sticker for unauthorised personnel on electrical boards
and boxes that consent access to live parts with the entire mbody (WARNING
AD01)
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2.16.6.2 Work on the electrical system – (Risk ID: 09.02)

Area: Z01 Electrical equipment RESIDUAL RISK: MEDIUM
PLr (EN 13849): -

SIL (EN IEC 62061): -
ACCIDENT SCENARIO
Consequence: 2.4 Electrocution
Situation: Maintenance on the electrical system (inspection, adjustment, substitutions).
Event: Risk of electrocution due to direct or indirect contact with parts that remain powered
even after the main switch has been sectioned:
- Interface signals
- Circuits upstream of the switch.
RESIDUAL RISK
Risk of electrocution due to direct or indirect contact with parts that remain powered even after the main
switch has been sectioned:
- Interface signals
- Circuits upstream of the switch.
LIMITATION MEASURES
Mechanical: - Wiring of electrical instruments in compliance with CEI EN 60204-1 standards
(SAFETY MEASURE Q03).
- Electrical cabinet doors may be opened only with a key entrusted to maintenance
personnel (SAFETY MEASURE Q02).
- The door to the electrical cabinet cannot be opened when the switch is in the ON
position.
Electrical: -
Informative: - Work on the electrical instruments, be they powered or not, may be carried out
only by expert personnel (EXP) and informed persons (INFP), as per the definition
provided for in CEI 11-27. CEI EN 60204-1 standards do not differ between work
carried out on electrical instruments that are not power and those that are live,
therefore not obligatorily requiring that the latter be carried out by Competent
Persons (COP) as per the definition provided for in CEI 11-27.
- Before intervening on any electrical equipment, identify the relative circuits on the
wiring diagram.
- Always check for residual tension before working on circuits.
Symbols: - Electrocution warning sticker on boards and boxes containing live parts
(WARNING PE01)
- Do not enter prohibition sticker for unauthorised personnel on electrical boards
and boxes that consent access to live parts with the entire mbody (WARNING
AD01)
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2.16.7 Rischi residui presenti durante gli interventi di lubrificazione/ingrassaggio
2.16.7.1 Lubrication/greasing – (Risk ID: 11.01)

PLr (EN 13849): -

SIL (EN IEC 62061): -
ACCIDENT SCENARIO
Consequence: 7.9 Poisoning
7.10 Sensitisation
Situation: Handling of lubricants and greases and/or parts that have come into contact with
lubricants or grease used to lubricate rollers, supports, gear motors, etc.
Event: - Various risks (7.9 poisoning, 7.10 sensitisation) deriving from skin or eyes coming
into contact with lubricants or ingestion of lubricants.
- Risk of environmental pollution deriving from lubricant spills.
RESIDUAL RISK
Risk of poisoning or sensitisation deriving from skin or eyes coming into contact with lubricants or
ingestion of lubricants.
- Risk of environmental pollution deriving from lubricant spills.
LIMITATION MEASURES
Mechanical: -
Electrical: -
Informative: Lubricants (greases and oils) are toxic and noxious. Follow the prodcer safety
information.
Always use personal protective equipment (PPE) for all tasks where there is a
foreseeable risk of coming into contact with lubricants.
Waste lubricants must be disposed of by orgnisations authorised to collect and
dispose of these types of substances.
Symbols: -
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2.16.8 Residual risks during SINGLE PITCH loading/unloading (work cycle)
2.16.8.1 SINGLE PITCH loading/unloading (work cycle) – (Risk ID: 12.01)

Stage: Use Initial risk: HIGH
Person: Operator
Area: Z02 Material loading/unloading area RESIDUAL RISK: LOW
PLr (EN 13849): d

SIL (EN IEC 62061): SIL2
ACCIDENT SCENARIO
Situation: Loading and unloading piece/s to/from the table.
Event: Risk of crushing resulting from the closing of the piece support devices.
Body part: Hands, fingers.
RESIDUAL RISK
Risk of crushing resulting from the closing of the piece support devices.
LIMITATION MEASURES
Mechanical: During loading/unloading stages, two protection measures are implemented for
reducing the risk and remedy to any misconducts by redundancy. These measures
are:
- Adjusting of the piece support devices, carried out by the maintenance technician
during machine setup.
- Two different pressure values (PROTECTION MEASURE M10) during
loading/unloading and processing stages.
Electrical: Check of the closing pressure of the piece support device.
Informative: The closing of the piece support device is performed by pressing the specific pedal
button located near the table. Once the piece has been put in place, keep the
hands away from the piece support devices, then step on the pedal to effect the
closing, which occurs at a reduced force compared to that used during the
processing cycle.
The piece support devices must be exclusively adjusted by the maintenance
technician in two different manners, described in the manual chapter on controls
and use.
Symbols: -
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2.16.8.2 SINGLE PITCH loading/unloading (work cycle) – (Risk ID: 12.02)

Stage: Use Initial risk: LOW
Person: Operator
Area: Z02 Material loading/unloading area RESIDUAL RISK: LOW
PLr (EN 13849): -

SIL (EN IEC 62061): -
ACCIDENT SCENARIO
1.8 Collision
Situation: Loading and unloading piece/s to/from the table.
Event: Risk of crushing and collision resulting from the piece/s falling from the table.
Body part: Hands, fingers, feet, lower limbs.
RESIDUAL RISK
Risk of crushing and collision resulting from the piece falling from the clamps.
LIMITATION MEASURES
Mechanical: -
Electrical: -
Informative: The piece must be loaded by correctly placing it on the specific support device.
After checking the stability of the piece, lock it by stepping on the specific pedal
located near the table.
The piece must be unloaded by stepping on the specific pedal located near the
table, to open the support device. Firmly grasp the piece, then step on the pedal to
open the support device, then remove the piece. Lay the piece on the floor or in
specific containers.
Symbols: -
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2.16.9 Residual risks existing in TANDEM processing cycle
2.16.9.1 TANDEM processing cycle - (Risk ID: 13.01)

Stage: Operation Initial risk: HIGH
Person: Operator
Area: Z02 material loading/unloading area Residual risk: AVERAGE
PLr (EN 13849): -

SIL (EN IEC 62061): -
ACCIDENT SCENARIO
Consequence: 1.1 Hitting
1.12 Perforation or puncture
Situation: Standing near the loading/unloading area.
NOTE: risk assessed after machine setup for changing from TANDEM processing
to SINGLE-STEP, loading/unloading working cycle.
Event: Risk of getting hit by tool fragments or by the tool itself, projected outward as a
result of a breakup.
Body part: Whole body
Face
Eyes
RESIDUAL RISK
After machine setup for changing from TANDEM processing to SINGLE-STEP, loading/unloading
working cycle, a risk remains of getting hit by tool fragments or the tool itself, projected outward as a
result of a breakup, if in the course of the setup procedure the central guard for the two axes (Y1-Y2) is
not reassembled (PROTECTION MEASURE M11).
REDUCTION MEASURES
Mechanical: The perimeter protections (PROTECTION MEASURE M04), the access doors
(PROTECTION MEASURE M05), the central protection installed between the piece
support devices (axes Y1 and Y2, PROTECTION MEASURE M11), and the
combinations of movable guards (PROTECTION MEASURE M06) have been
properly designed to withstand any tool breakage and allow containment.
Electrical: -
Informative: At the end of the TANDEM processing cycle, the maintenance technician who carry
out machine setup is required to reassemble the central guard (PROTECTION
MEASURE M11) before enabling the SINGLE-STEP, loading/unloading working
cycle. Follow the procedure described in the instruction manual.
NOTE: The ejection of tool fragments is reduced to a minimum, at least along the
direction of two horizontal axes (ref. EN 848-3:2007+A2:2009-, section
5.3.7.1.2.3.1).
Pictograms: -
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2.16.10 Residual risks during HOLD-TO-RUN movements (portable control)
2.16.10.1 HOLD-TO-RUN movements (portable control) – (Risk ID: 15.01)

Area: Z05 Portable pushbutton control RESIDUAL RISK: LOW
PLr (EN 13849): d

ACCIDENT SCENARIO
1.8 Impact
Situation: Use of HOLD-TO-RUN controls on the portable control panel.
Event: Risk of crushing and impact caused by the movement of parts controlled by the
relative controls.
Body part: Entire body, head, upper limbs, hands.
RESIDUAL RISK
-
LIMITATION MEASURES
Mechanical: - The controls are located on a pushbutton panel that is enabled while the operator
is standing inside the safety guards.
- The internal moving parts are protected by special fixed buards (SAFETY
MEASURE M08).
Electrical: Hold-to-run controls that allows moving one axis at a time (SAFETY MEASURE
M09). The controls are located on a portable panel and must be enabled by
pressing the relative pushbutton on the panel.
Informative: - Machine movements carried out usiing the controls on the portable panel must be
carried out by an Expert Person who has been authorised, trained and informed
regarding the risks present in the area inside the machine enclosure.
- During use of the pushbutton panel, only one Person may be inside the machine,
holding the remote portable pushbutton control and controlling the movements
while standing at a safe distance.
Symbols: -
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2.16.11 Residual risks during height work
2.16.11.1 Height work – (Risk ID: 16.01)

PLr (EN 13849): -

SIL (EN IEC 62061): -
ACCIDENT SCENARIO
Consequence: 1.11 Slipping, tripping and falling
Situation: Maintenance work required by the manufacturer for which the maintenance
operator must work at height.
Event: Risk of slipping, tripping and falling off permanent access equipment and/or
machine structures.
Body part: Entire body, head.
RESIDUAL RISK
There is a risk of slipping, tripping and falling when climbing, descending or standing on ladders,
scaffolding and/or permanent footbards,
LIMITATION MEASURES
Mechanical: There is no permanent access equipment.
Electrical: -
Informative: - It is forbidden to climb onto machine structures from any point that is not equipped
for climbing.
- Always use permanent access equipment on the machine for all height work.
- Where the machine is not fitted with permanent access equipment, use ladders,
scaffolding and/or moving platforms.
- Wear personal protective equipment /PPE) suited for height work.
- Move carefully when climbing or descending ladders or standing at heights.
Symbols: -
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2.16.12 Residual risks during adjustments with laser devices
2.16.12.1 Adjustments with laser devices – (Risk ID: 17.01)

Stage: Maintenance Initial risk: MEDIUM
PLr (EN 13849): -

SIL (EN IEC 62061): -
ACCIDENT SCENARIO
Consequence: 6.2 Injury to eyes and skin.
Situation: Standing near the laser adjustment device.
Event: Risk of injury to eyes looking directly into the laser beam.
Body part: Eyes.
RESIDUAL RISK
Risk of injury to eyes looking directly into the laser beam.
LIMITATION MEASURES
Mechanical: The photocells are positioned in such a way as to avoid the laser beam from
pointing directly into the operator’s eyes.
Electrical: -
Informative: Take care never to look directly into the laser beam.
A warning sticker bearing the warning below is located near the lawer:
CLASS 2 LASER
DO NOT STAND NEAR THE LASER BEAM.
Symbols: Placement of a sticker warning of the presence of a class 2 laser (WARNING
AP05)
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2.16.13 Residual risks present during safeguarding work
2.16.13.1 Safeguarding work– (Risk ID: 18.01)

Person: Operator
Area: Z03 Inside the machine RESIDUAL RISK: MEDIUM
PLr (EN 13849): c

ACCIDENT SCENARIO
Situation: Being trapped inside the all-around enclosures.
Event: Various risks deriving from the unexpected start-up of machine moving parts.
RESIDUAL RISK
Various risks deriving from the unexpected start-up of machine moving parts.
LIMITATION MEASURES
Mechanical: The access doors are designed to avoid involuntary closing.
Electrical: The door, once it has been closed, must be reset by pressing the relative reset
pushbutton.
Informative: In case of becoming trapped, move away from the moving machine parts and
towards the closest door. If necessary, press the closest emergency stop
pushbutton. The door may be unlocked using the unlocking key located near the
interlocking device.
Symbols: -
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2.16.14 Residual risks during interventions of telephone support and remote

assistance
2.16.14.1 Telephone support and remote assistance interventions - (Risk ID: 19.01)

Stage: Troubleshooting and repair Initial risk: AVERAGE
Person: Maintenance technician
Area: Z00 All areas Residual risk: AVERAGE
PLr (EN 13849): -

SIL (EN IEC 62061): -
ACCIDENT SCENARIO
Situation: Troubleshooting interventions via telephone support with the manufacturer’s
customer service, and machine control logic possibly connected to teleservice
lines, with possibility of remote control.
Event: Various hazards arising from unexpected machine movements.
Body part: Whole body.
RESIDUAL RISK
During troubleshooting interventions via telephone support with the manufacturer’s customer service,
and machine control logic possibly connected to teleservice lines, with possibility of remote control,
several residual risk remains, resulting from unexpected movements of the machine.
REDUCTION MEASURES
Mechanical: -
Electrical: -
Informative: Troubleshooting interventions must exclusively be carried out by specialized and
authorized maintenance technicians. It is mandatory to coordinate troubleshooting
activities with the technicians from the manufacturer’s technical support service.
Follow the procedure described in the instruction manual.
Pictograms: -
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CHAPTER 3 – Machine description and technical data
CHAPTER
3 Machine description
and technical data
Chap. 3
- 1/28 -
INDEX
3 Machine description and technical data ..................................................................................................... 1
3.1 Description of machine functioning ............................................................................................. 3
3.2 Characteristics of machinable materials......................................................................................3
3.3 Maximum sizes of pieces to be loaded for machining ...............................................................4
3.4 Possible machining ........................................................................................................................ 4
3.5 Manufacturing features .................................................................................................................. 6
3.6 Machine layout ................................................................................................................................ 7
3.6.1 Machine operating diagram ............................................................................................................ 7
3.7 Description of main units............................................................................................................... 9
3.7.1 Machine body (X-axis) .................................................................................................................... 9
3.7.2 Strut (Z-axis) ................................................................................................................................... 9
3.7.3 Machining heads (B-A axis) .......................................................................................................... 10
3.7.4 BCK : tool holding shaft (OPTIONAL) ........................................................................................... 13
3.7.5 Spindle extension with ceramic bearings (OPTIONAL) ................................................................ 14
3.7.6 Tool changer (OPTIONAL) ........................................................................................................... 14
3.7.7 “TGV” - Variable Geometry Tables (Y1 and Y2 axes) .................................................................. 15
3.7.8 Depression table (OPTIONAL) ..................................................................................................... 16
3.7.9 “TGV-TRC” - Rotating Variable Geometry Tables (OPTIONAL) ................................................... 16
3.7.10 “TGV-CN” - Numerically Controlled Variable Geometry Tables (OPTIONAL) .............................. 16
3.7.11 Tilting TGV shelves (OPTIONAL) ................................................................................................. 17
3.7.12 Headstock/tailstock NC device (OPTIONAL) ................................................................................ 17
3.7.13 Standard workpiece locking .......................................................................................................... 18
3.7.14 Optional workpiece locking ........................................................................................................... 18
3.7.15 Electrical cabinet .......................................................................................................................... 20
3.7.16 Numerical control .......................................................................................................................... 20
3.7.17 Centralized grease lubrication system .......................................................................................... 21
3.7.18 Centralized grease lubrication system .......................................................................................... 22
3.7.19 Safety guards and devices ........................................................................................................... 22
3.8 Technical data ............................................................................................................................... 23
3.8.1 Machine technical data ................................................................................................................. 23
3.8.2 Machine electrical wiring data....................................................................................................... 24
3.8.3 Power and consumption ............................................................................................................... 24
3.8.4 Pneumatic system data (compressed air)..................................................................................... 24
3.8.5 Static and dynamic loads .............................................................................................................. 24
3.8.6 Overall measurements.................................................................................................................. 24
3.8.7 Spaces for use and maintenance ................................................................................................. 25
3.8.8 Tool technical characteristics........................................................................................................ 25
3.9 Machine identification .................................................................................................................. 26
3.10 EU Declaration of Conformity ..................................................................................................... 27
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3.1 Description of machine functioning

The TWIN work center with 6 interpolated axes has a high-stiffness, portal structure, particularly
suitable for the production of elements of chairs, tables, beds, frames, stairs and musical
instruments.
The machine is not designed to be used in line with other machines. The material to be machined
is loaded and unloaded automatically onto the machine work surfaces.
The machine has been designed for machining wooden pieces or similar materials, whose
characteristics are defined in the technical data sheet. The processing occurs at predefined
operator workstations, where the operator can carry out the loading/unloading of the materials.
During the processing, the piece is supported by support devices (i.e. clamps and/or user-built
equipment), placed on the support surface (TABLE). The processing is performed by tools fixed on
a 5-axes machining head. The machine is designed for single-head operation.
The oversized the beams allows for wide sideways movements of the heads (X axis).
The elevated dynamics of the TWIN work station derives from the use of precision reducers with
no backlash and that require no periodic adjustments, as well as from the perfect automatic
lubrication "from the inside out". In addition to traditional programming systems, the DOUBLE JET
work station may be programmed using the exclusive Bacci PITAGORA Software, which best takes
advantage of the elevated machining dynamics, thereby reaching exceptional performance yields.
3.2 Characteristics of machinable materials

Machinable materials are:
• Wood (hardwood, plywood, block board, wood strips, engineered woods, laminar woods,
hollow cored woods).
• Wood derivatives (hardboard, MDF, OSB) or similar materials*.
• Materials defined as plastics or composites, that is polymers (for example, PVC, ABS,
PMMA, Lexan), resins (for example glass fiber reinforced plastics), thermoplastic materials
(meaning materials resulting from treated polymers) and rubber materials.
* similar materials: materials that have machining parameters for milling, boring and cutting that are
comparable to the machining parameters for wood materials (for example: urea resins, PVC, ...)
Machining materials other than those mentioned above is not permitted.
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3.3 Maximum sizes of pieces to be loaded for machining

The maximum sizes of pieces to be loaded for machining must not be greater than those specified
in the table below.
TYPE DESCRIPTION
Minimum length 210 mm
Maximum width 150 mm (200 on request)
Maximum height 60 mm (100 on request)
Data regarding piece machinability must be calculated each time, case by case, taking into
account the maximum movements that may be carried out by the working unit used for machining,
the position of the piece on the work table, the size of the tools and the space taken up by the
other groups present on the working unit.
Before starting machining, always check that the piece is held firmly and blocked properly.
Minimum sizes are easy to define in that the gripping intensity of the vacuum holding system
depends on piece porosity, thickness and size.
Moreover, the minimum gripping intensity is different for each type of tool used.
In any event, the manufacturer PAOLINO BACCI S.r.l. is available for further information.
3.4 Possible machining

The machining that may be carried out by the machine is described and shown below. Some of the
types of machining shown below may be carried out only with the aid of optional machining units.
MACHINING FIGURE
Vertical and horizontal

boring

milling
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MACHINING FIGURE
Flat surface milling within
distance -

milling
4/5 axis milling within

distance
Cutting
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3.5 Manufacturing features
The machine is divided in two work stations. The control panel, located on one side of the
machine, contains separate controls for each station.
The machine is composed of the following main groups or units:
• Single-strut machine body

• Z-axis carriage
• Y-axis carriage
• X-axis
• Work heads / electric spindles
• Numerical control
• Centralized lubricating and greasing system
• Electrical cabinet
• External safety enclosure.
The optional units that may be provided (on request) with the machine are described here
following.
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3.6 Machine layout
3.6.1 Machine operating diagram

The figure below represents the machine operating diagram: specifically, it represent the axes and relative
movements carried out by the operating units.
STRUT
B-A HEAD
B A
TABLE
Y1 Y2
HEADS MACHINE BODY PIECE TRADENAME

1 MOVABLE STRUT (X,Z) , HEAD (B,A) TABLE (Y1,Y2) TWIN
The axes controlled by the machine are:

• X axis
• Transversal axes of the Y axis carriage
• Vertical Z axes of the Z axis carriages
• Rotating A axes of the operating heads
• Rotating B axes of the operating heads
Each axis has a positive and a negative direction. The diagram shows the positive direction for
each axis. All movements take place on over-sized bearing skids that ensure solidity and reliability
over time. All movements are driven by brushless motors (maintenance free) and preloaded
circulating ball screws that provide for high accelerations.
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All screws and skids are automatically lubricated from the CN and lubrication is checked along the
line by a control sensor.The main units and optional units making up the machine are listed below
2
3
4 5 5 4 1 8
POS. COMPONENT DESCRIPTION

Machine body:
1
Single-strut machine structure
Strut (Z-axis) and machining head (B-A axis)
2
Set of devices that allow execution of the processing required.
X-axis
3
Support and movement carriage of the machining head along the X-axis.
Piece support devices (axes Y1 and Y2).
4
Piece support devices that allow processing along the Y-axis.
Tables
5
Units on which the piece support devices slide.
Enclosure:
6 an all-around safety guard that includes the entire machine. Access inside the enclosure
takes place through doors fitted with safe-access micro-switches.
Lubrication system:
7 automatically distributes lubricant to all connected points: skids and aces and ball bearing
screws.
Electrical cabinet:
8 contains the main controls and electronic equipment required to manage machine
operation, including numerical control and operator panel.
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3.7 Description of main units

3.7.1 Machine body (X-axis)
The machine body is made up of a strongly ribbed, stabilized steel structure, of considerable
section, to ensure maximum stiffness and straightness over time, under any load conditions.
On the machine body, the strut sliding guides along the X-axis are mounted [1].
3.7.2 Strut (Z-axis)
The strut (1, Z-axis) is the set of devices that allow the tools to machine the workpiece.
It is made up of a support and movement structure for the revolving, spindle-holder machining
head [2], on which the tools are mounted. The head slides along the vertical direction and rotates
around its A and B axes. Such rotating movements are continuous and interpolated, and are
controlled without any backlashes or periodical calibrations, by two precision gearmotors.
As for the linear axes, the sliding occurs on oversized roller bearings shoes, to ensure absolute
stiffness and reliability.
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All movements are controlled by brushless motors (no need for maintenance) and high-precision,
preloaded-balls, recirculation screws that allow travel speed up to 100 m/min.
The lubrication of all screws and shoes is automatic, numerically controlled and monitored by
control sensors during the travel.
As for the rotating axes, the two rotating movements of the head (B and C axes) are continuous
and interpolated, and are controlled without any backlashes or periodical calibrations, by two
precision gearmotors.
3.7.3 Machining heads (B-A axis)
Type 2+2:
It consists of two electrospindles with double exit per side, arranged in superimposed cross. Each
electrospindle has at the ends of its shaft (diam. 40 mm) two tool fittings with preset stop.
Available versions:
• 10,0 HP / ER 32
• 12,5 HP / ER 40
• 16,0 HP / ER 40
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Type 4:
It consists of four independent, coplanar electrospindles, each equipped with tool fitting and preset
stop.
Available versions:
• 10,0 HP / ER 32
• 12,5 HP / ER 40
Type 4, Prismatic:
It consists of four independent, coplanar, staggered electrospindles, each equipped with tool fitting
and preset stop.
Available versions:
• 10,0 HP / ER 32
• 12,5 HP / ER 40
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Type 3+2:
It consists of three independent, coplanar spindles, plus a double-exit electrospindles.
All of them are equipped with tool fitting and preset stop.
Available versions:
• 10,0 HP / ER 32
• 12,5 HP / ER 40
Spindles reliability and their duration over time are guaranteed by standard ceramic bearings.
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Whatever the head used, through the “Power Control” function, the NC slows down the speed of
the axes when the absorbed power exceeds 160% of rated power. All the (high-power)
electrospindles are driven by an electronic inverter, with rotating speed from 0 to 24.000 rpm, and
10 Hp power (18.000 rpm for higher power).
It is advisable to equip the machine with the second (optional) inverter, to speed up the passage
from one spindle to the next (from 6-7 sec to 1 sec).
The electrospindles are capable of both left-handed and right-handed rotation. La potenza
massima viene erogata già a 12.000 giri/minuto e viene mantenuta costante fino a 24.000
giri/minuto
Maximum diameter and maximum length of the tool, depending on configuration:
Please refer to the annexed data sheet.
Standard configuration:
• 4 ring nuts for ER32 or ER 40 grippers

• 4 ER32 or ER 40 grippers (2 x φ 20 mm, 1 x φ 16 mm, 1 x φ 10 mm)
3.7.4 BCK : tool holding shaft (OPTIONAL)
The high-rigidity and high-precision BCK shaft with taper shank is fitted onto the spindle without the
use of a clamp.
It is supplied complete with ring nut, counter ring nut and tightening wrench.
• ER 32 – M10 with φ 25 mm shaft, 55 mm or 85 mm long, M 10 thread at the head for tool

attachment, right or left rotation.
• ER 40 – M10 with φ 30 mm shaft, 55 mm or 85 mm long, M 10 thread at the head for tool
attachment, right or left rotation.
• ER 32 – ER 20 with φ 25 mm shaft, 55 mm or 85 mm long, ER 20 at the head for tool

attachment, right rotation.
• ER 40 – ER 25 with φ 30 mm shaft, 55 mm or 85 mm long, ER 25 at the head for tool
attachment, right rotation.
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3.7.5 Spindle extension with ceramic bearings (OPTIONAL)
For ER 32 or ER 40, it extends the spindle to 170 mm.

Equipped with 2 pairs of angular-contact, ceramic bearings, 12.000 rpm max.
It guarantees the same characteristics as the standard spindle.
It is fixed with 4 screws directly on the original spindle.
3.7.6 Tool changer (OPTIONAL)
Upon request, the work center can be equipped with a numerically controlled tool changer
(additional interpolated axis) without any pneumatic movement, in order to ensure maximum
precision and reliability. The tool-holder movement occurs without any kind of backlash or
interference, thanks to an extremely accurate gearmotor (the same used for the rotating
movements of the machining head).
The maximum diameter of the tools which can be housed in the tool changer is 200 mm.
The tool changer may be equipped, depending on specific request, with “ISO 30” or “HSK63F” tool
fittings.
The tool-holder is provided with dust protection and can be 6 or 16 positions; it is mounted on an
independent structure located aboard the machine.
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3.7.7 “TGV” - Variable Geometry Tables (Y1 and Y2 axes)
The TWIN work center is equipped with two independent work tables [1], that are numerically
controlled and movable along the Y axis (height from the floor for loading/unloading = 1050 mm)
for oversize processing and translation: in this way, the head can operate in conditions of
maximum stiffness and therefore accurately.
The planar support surface of each table is made up by two steel shelves with adjustable center
distance [2].
The shelves are capable of depression and the surface has a grid of 50 x 50 mm.
On both the long sides of the shelf two dovetail millings exist, that allow anchoring of the pneumatic
presser, easily adjustable along the Y-axis, for optimal locking.
2 2
1 1
This solution allows:
• by adjusting the shelves at a distance less than the length of the workpieces, to process the
ends of short elements without having to lift the pieces, to avoid collision.
• by distancing the shelves to the maximum, to let the machining head enter between the
shelves, to machine the internal sides.
• to drill from the bottom up, even at central positions of the piece.
• to machine very long pieces, by placing the shelves parallel to the X-axis.
• to halve the number of counterprofiles.
• to halve the setup time.
The two tables can be synchronized by the numeric control software, for machining very long
pieces. This operating mode is defined as “TANDEM processing”.
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3.7.8 Depression table (OPTIONAL)
Made up of aluminum, variable size, 50 mm grid and equipped with lids and threaded holes, it can
be mounted directly on the TGV or its supports, to facilitate locking of flat-base pieces, and for
machining the upper side of the workpiece.
3.7.9 “TGV-TRC” - Rotating Variable Geometry Tables (OPTIONAL)
The patented “TGV” variable geometry tables described above may be mounted on continuously
rotating aluminum boards, around a vertical interpolated axis (additional “A” interpolated axis). The
max center distance of the shelves is 1170 mm and their length is 1130 mm.
Due to the rotation, all the 4 sides of the table may be turned toward the machining head;
therefore, it is not only possible the complete machining of the 5 sides of a workpiece, but also the
positioning of more details on the same counterprofile, hence reducing the setup time.
The rotating table also allows to increase the contouring dimensional capacity up to 1800 mm.
3.7.10 “TGV-CN” - Numerically Controlled Variable Geometry Tables

(OPTIONAL)
In this kind of table, the center distance of the shelves is interpolated and numerically controlled
along the “X” direction. This allows coaxial, mirrored, simultaneous machining, therefore halving
the processing time. The two shelves can be positioned by the numerical controller at a maximum
opening of 1185 mm, and remain fixed during machining.
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3.7.11 Tilting TGV shelves (OPTIONAL)
The tilting TGV shelves may be added to standard TGV tables (without TGV-TRC or TGV-CN),
manually operated by means of a handwheel, equipped with a specific measuring siko, around the
Y-axis (from 0° to +90° or -90°); this allows to:
• Place curved workpieces (concave or convex) without the need for complex piece holders.
• By automatically tilting also the pressers fitted to the tilting shelves, the piece can be locked
perfectly in line, without any need for marking its surfaces.
3.7.12 Headstock/tailstock NC device (OPTIONAL)
In place of one of the tilting TGV shelves, on the machine tables a headstock/tailstock device can
be mounted, with numerically controlled rotation, interpolated with the remaining machine axes.
This device allows any kind of machining on the 4 long sides of the piece.
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3.7.13 Standard workpiece locking
The standard version of the machine is equipped with 4 pneumatic pressers (2 for each table)
easily anchored to the shelves by means of dovetail guides, for optimal locking.
3.7.14 Optional workpiece locking
For special applications (press-curved wood) specific pneumatic pressers can be supplied, with
holding power up to 2000 kg. They also can be positioned on the long sides of the TGVs.
Further possibilities for special applications are special pneumatic pressers, adjustable in height,
for locking the pieces without any need for making counterprofile piece-holders.
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Suction cups of different sizes are also available. The cups are easily placed along the TGV arm,
by means of the dovetails grooves.
If necessary, the suction cups may also be equipped with a little lifting piston, to avoid scratching
the workpiece.
Finally, vacuum pumps are available, of several sizes (100, 165, 200, 250 m3/h) and characteristics
compatible with the kind of applications required.
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3.7.15 Electrical cabinet
The electrical cabinet contains the main controls

3 and electronic equipment required to manage
machine operations, including the numerical
control CN (1) and the operator panel (2).
1 The electrical cabinet in fitted with an air
conditioning system (3) to keep the temperature
2 inside the cabinet low and constant and thus
guaranty proper functioning of the numerical
control CN.
The entire cabinet is protected by a dust-proof
covering.
POS. NAME
1 Numerical control with display.
2 Main operator panel
3 Air conditioning
3.7.16 Numerical control

The numerical control is a characteristic of tooling machines, called “numerical control machines”
or “CN” machines. The machining movement of these machines during tooling is directed by a
computer built into the machine itself that controls movements and functions based on a
specifically defined work (machining) program.
A CN machine simply executes the program that has been set, regardless of what happens around
the machine, and the operator’s task is to prepare the pieces to be machined and intervene if
anything unexpected takes place.
CN machines must always run under the supervision of an operator authorized to use the machine.
Consult the documentation attached to this manual for a description of the numerical control
system installed on the machine.
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3.7.17 Centralized grease lubrication system
The centralized, automatic lubrication system is

1
connected by means of progressive distributors
to all the recirculating ball carriages and all the
axis worm screw nuts.
The system lubricates all the connected points
at the preset greasing intervals, with the grease
in the greasing tank (1).
POS. NAME
1 Grease tank
2 Grease pump
3 Pressure gauge for working pressure
The pump (2) is connected to the lower part of the tank and is controlled by a simple effect piston
driven by compressed air.
Return to starting position is censure by a spring. A spring with a presser disk is installed inside the
tank. The system includes an electric minimum level sensor and a filling filter.
Chap. 3
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3.7.18 Centralized grease lubrication system
The centralized, automatic lubrication

system is connected by means of
progressive distributors to all the
recirculating ball skids and all the axis worm
screw nuts.
2 The system lubricates all the connected
points based on the lubricating time settings,
using the oil contained in the tank (1).
POS. NAME
1 Oil tank
2 Oil pump
3 Pressure gauge for working pressure
3.7.19 Safety guards and devices
Safety guards and devices are installed on the machine to protect mechanical moving parts (for
example, chains, gears, transmissions and moving organs) described in the chapter “2 Machine
safety devices”, paragraph “2.8 Safety measure”.
The efficiency of the safety devices must be assessed after the machine has been installed at the
end user’s site, at which point the risks related to interconnection of the machine with the other
machines in the plant may be evaluated, providing for any additional guards and/or safety devices
that may be deemed necessary.
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3.8 Technical data
INFORMATION!
The paragraphs that follow contain the main technical data for the machine, or in any event
the minimum and maximum obtainable performance output; this data may differ based on
specific customer requirements.
3.8.1 Machine technical data
TYPE DESCRIPTION
Number of interpolated axes 6
Axis strokes
Longitudinal X-axis (standard) 2200 mm
Longitudinal X-axis (optional) 3400/4400 mm
Transverse Y-axis 1800 mm
Contouring capacity along Y direction 1200 mm
Z vertical axis 1250 mm
B rotating axis unlimited
C rotating axis 400°
Speed
X-axes 100 m/min
Y and Z axes 60 m/min
Spindles
Rated power (S1) 10 Hp / 7,5 kW
Rotation speed 0 - 24.000 1/min
Direction of rotation Clockwise and counterclockwise
Machining tables
Number of tables 2
Dimensions including stroke

X-axis = 2200 mm 4500x5100x2200 mm
X-axis = 3400 mm (optional) 6000x5100x2200 mm
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3.8.2 Machine electrical wiring data
TYPE DESCRIPTION
Electrical voltage in Volts See machine plate
Electrical frequency in Hz See machine plate
Electrical absorption in kW See machine plate
Contemporaneity factor 0,7
3 phases + 1 earth
Type of connection Star connection:
TT;TN-C;TN-S
Max. resistance to ground 2 Ohm
Max. power See machine plate
Type B device
Protection Delayed action (0.3 sec.)
0.3A adjustable differential current.
3.8.3 Power and consumption

System power and consumption data are contained in ANNEX B TECHNICAL DIAGRAMS AND
GENERAL INFORMATION.
3.8.4 Pneumatic system data (compressed air)

The pneumatic system to which the machine is connected must meet the following requirements.
The machine will work efficiently only if all the specifications are met.
TYPE DESCRIPTION
Recommended diameter for the
1/2"
compressed air pipe line
25 mm external
Connection diameter for rubber pipe:
17 mm internal
Air consumption at 6 bar Based on the model
Optimal line pressure 6.5 bar
HAZARD!
Dust, condensation and oil may damage the spindle.
Use only air that is clean dry, filtered, not lubricated, and condensation-free.
3.8.5 Static and dynamic loads
Machine static and dynamic loads are shown in the structural work installation layout drawings.
3.8.6 Overall measurements

The overall measurements of the machine are shown in the main layout drawing (see ANNEX B
TECHNICAL DIAGRAMS AND GENERAL INFORMATION).
Chap. 3
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3.8.7 Spaces for use and maintenance
INFORMATION!
Space requirements for use and maintenance must be verified on the machine’s main installation
layout drawing, which must always be consulted.
The presence of structural elements such as, for example, walls, columns, etc., or work equipment
in the area destined to machine use and maintenance may render proper installation impossible.
The user may therefore be required to carry out structural work to adapt the site to machine
installation before the machine may be installed and started up.
Space requirements for use and maintenance are shown in the main layout drawing (see ANNEX
B TECHNICAL DIAGRAMS AND GENERAL INFORMATION).
3.8.8 Tool technical characteristics
Use only tools having the diameters and weights shown in the table below.
COUPLING SIZE MAX TOOL SHAFT ROTATION SPEED MAX TOOL MAX TOOL
DIAMETER (MM) (RPM) DIAMETER (MM) WEIGHT (KG)
6000 / 9000 150 10
9000 / 12000 130 7
ER40 25
12000 / 15000 110 5
15000 / 18000 80 5
6000 / 9000 140 4
9000 / 12000 130 4
ER32 20
12000 / 15000 110 2.5
15000 / 18000 80 2.5
DANGER!
Risk of flying tool parts
Improper tool balancing may cause:

• The tool to break, or
• The tool to come free from the spindle.
• Balance tools and tool holders in G1. Rebalance every time they are sharpened.
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3.9 Machine identification
The machine and electrical board identification data are shown on the identification plates. The location of
the identification plates is shown in the figure below.
• The symbol is present only on the machine identification plate and only for machines
marketed and sold within the European Community, accompanied by the relative EC declaration of
conformity, as per annex II A of the Machinery Directive 98/37/CE.
• The symbol is not present on machines marketed and sold in countries that do not belong to
the European Community.
INFORMATION!
Do not remove the machine or electrical board identification plates. If the plates are damaged, always
contact the manufacturer.
The location of the plates is shown in the general layout (see ANNEX B TECHNICAL DIAGRAMS
AND GENERAL INFORMATION).
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3.10 EU Declaration of Conformity
If the machine is to be sold on the European market, it will be accompanied by its related EU declaration of
conformity as per Annex II A of Machinery Directive 2006/42/EC. The signed EC declaration of conformity is
provided upon delivery of the machine; please see a facsimile of said declaration below.
EU DECLARATION OF CONFORMITY
(according to 2006/42/CE)
THE MANUFACTURER PAOLINO BACCI S.R.L.

VIA PALERMO 32
56021 CASCINA (PISA) - ITALY
Represented by Mr. AGOSTINO BACCI, Legal Representative
HEREBY DECLARES THAT THE MACHINE
NAME (FUNCTION)
TYPE (MODEL/TRADE NAME)
SERIAL NUMBER
YEAR OF MANUFACTURE
IS CONFORMANT TO ALL THE PROVISIONS OF DIRECTIVES
2006/42/EC (MACHINERY)
2004/108/EC (EMC)
DESIGNATES:
as person authorized to prepare the Technical File the company Paolino Bacci S.r.l.,
via Palermo 32 56021 CASCINA (PI) - Italy.
CASCINA, THE LEGAL REPRESENTATIVE

A.BACCI
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Chap. 3
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CHAPTER 4 – Installation
CHAPTER
4 Installation
Chap. 4
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INDEX
4 Installation ................................................................................................................... 1
4.1 Information required on handling of loads and installation .................................................................3
4.1.1 Loads handling equipment provided by the customer ................................................................................ 4
4.1.2 Installation equipment provided by the customer ....................................................................................... 5
4.1.3 Installation preparations made by the customer ......................................................................................... 5
4.2 Packaging, handling, transport ...............................................................................................................6
4.2.1 General safety recommendations for load handling ................................................................................... 6
4.2.2 Information regarding shipment and delivery ............................................................................................. 8
4.2.3 Packaging and shipment precautions and tactics ...................................................................................... 9
4.3 Preparing the machine for shipment ....................................................................................................11
4.3.1 Disconnecting the electrical cabinet ......................................................................................................... 11
4.3.2 Mechanical preparations for transport ...................................................................................................... 12
4.4 Component and load group identification and handling ....................................................................13
4.5 Loading, transportation and unloading ................................................................................................16
4.6 Installation site requirements ................................................................................................................17
4.6.1 Floor specifications .................................................................................................................................. 17
4.6.2 Ambient data ............................................................................................................................................ 17
4.6.3 Illumination and aeration .......................................................................................................................... 18
4.6.4 Dust removal system ................................................................................................................................ 18
4.7 Assembly .................................................................................................................................................18
4.7.1 Anchoring the machine.............................................................................................................................18
4.7.2 Removing safety guards and blocks used for transportation .................................................................... 20
4.8 Connection to power supplies ..............................................................................................................20
Chap. 4
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4.1 Information required on handling of loads and installation
The following paragraphs provide the minimum information required on how to handle loads correctly
and install the machine.
For installation always refer to this manual and the documents mentioned in the different procedures.
This chapter contains all the necessary information on the installation step of the machine.
This step includes the preparation, loading and unloading of the machine for transport purposes.
Furthermore it describes the positioning of the machine components and its fastening to the floor. Finally,
it illustrates how to assemble the components removed in order to facilitate transport and connect the
machine to the electric and pneumatic system.
All operations described in the Installation chapter must be performed by qualified personnel authorized
by PAOLINO BACCI S.r.l.
Chap. 4
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4.1.1 Loads handling equipment provided by the customer

For handling loads and installing the machine it is necessary to have the equipment listed in the following
tables.
Upon receiving the machinery, unless otherwise agreed, all the material must be available in the
installation site.
LOADS HANDLING EQUIPMENT 1 of 1

EQUIPMENT
Crane
Stacker
Rocker arm
Galvanized screw pin shackles
Hoisting accessories (e.g. chains, belts, lashing

ropes)
INFORMATION!
The choice of the means to use for handling loads must be based on the evaluation of the
mass to hoist and the existence of environmental limitations, such as the height of the
installation site and accesses.
Chap. 4
- 4/20 -
4.1.2 Installation equipment provided by the customer
INSTALLATION EQUIPMENT 1 of 1
EQUIPMENT
Extension leads
Drill with drill bits
Grinding wheel with disks for metal
Welding machine
4.1.3 Installation preparations made by the customer
The installation site must be equipped with the following:
• 220 volt power supply points, close to the machine assembly site, to which the different work
equipment (drills, welding machine etc.) can be connected
• A telephone line with Internet access.
• Any necessary civil works must be implemented and the foundations and/or installation site must
be prepared.
Chap. 4
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4.2 Packaging, handling, transport
The following paragraphs provide the main information on the preparation of the machine for transport or
shifting. Certain machine parts are actually disassembled before transport to facilitate handling or to
reduce the maximum dimensions of the machine. Thus the maximum height of the machine is reduced
less than 2.5 m and the machine can be transported in a standard truck or inside a container.
The following paragraphs also include the main information on how to handle the machinery; they make
reference to the procedures to adopt, the means used and safety measures.
4.2.1 General safety recommendations for load handling
Given the specific nature of operations, it is obligatory to employ informed and trained personnel who will
work using hoisting means and will be aware of the operational and safety procedures to follow when
handling loads.
Before starting the transport of the machine and its components, consult the shipment list for information
on sizes.
During the loads hoisting and handling operation it is OBLIGATORY to abide by the following rules:
• IT IS OBLIGATORY that all load hoisting and handling be carried out only by specialized and
authorized personnel.
• IT IS OBLIGATORY to use personal protective equipment (PPE), such as safety footwear, work
wear, gloves for protection against crushing, safety helmet and harness for height work.
• IT IS OBLIGATORY that only personnel authorized for load handling work in the work area, in
compliance with common safety regulations that require safety areas around suspended loads,
lift-truck and/or moving overhead traveling cranes.
IT IS FORBIDDEN:
• It is forbidden to allow access to load handling safety areas to unauthorized personnel.

• It is absolutely FORBIDDEN to pass or stand under suspended loads.
Take heed of the following WARNINGS:
• Parts weighing more than 25 kg must not be handled manually. The barycenter for these parts is
shown on the part itself and they are fitted for hoisting by means of appropriate accessories
(harness, ropes, eyebolts, anchor bolts, .....).
• Assess the safest route and trajectory before hoisting a load.
• Use only ropes or chains that allow guiding the load while standing at a safe distance.
• Except for during stop and start, handling must take place without speeding up or slowing down
the load movement and avoiding jolts or impulse-type movements.
Chap. 4
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• Before hoisting the load completely, always check that hoisting is aligned with the barycenter of
the load being hoisted; if necessary, adjust the position of the hoisting equipment or redistribute
the loads.
• During horizontal movements, avoid pitching as much as possible, especially during movement
start-up or stop.
• Changes in direction must take place after a full stop from load standstill.
• As far as possible, the hoisted load must be kept away from obstacles and as closet o the ground
as possible.
• If the case bears the symbols shown below, crossed out, that type of hoisting for the load in
question is expressly prohibited.
• To rest the machine onto the platform of a truck or on the ground temporarily, the resting surface
must first be equipped with wood strips, all of equal height, positioned so as to provide a stable
resting surface and avoid damage to machine parts (where possible, rest the machine on its
side).
• The machine and or the equipment and components must be lowered to the ground slowly and
carefully, to avoid damage.
• Inspect the load hoisting equipment (hooks, harness, chains, eyebolts, anchor bolts) thoroughly
before use.
• If defects are found, replace the accessories with new ones, making sure that the replaced
hoisting equipment is put out of use definitively. Possible defects include:
o Absence or illegibility of labels bearing the load capacity;
o Presence of cuts, holes or rips on synthetic straps;
o Twisted or crushed points on ropes or metal cables;
o Signs of corrosion on metal parts;
o Abrasions and signs of wear due to excess friction on components.
• Cuts are the main cause of breaking of synthetic straps. Cuts are generally produced when the
straps rub against sharp edges on the load being handled.
• To ensure the integrity of straps, and therefore hoisting safety, we suggest inserting a soft
material along the edges of the load where it comes into contact with hoisting straps.
Chap. 4
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4.2.2 Information regarding shipment and delivery

The machine is shipped in perfect working conditions after having undergone general testing in our plant.
Based on the type and size of the components to be shipped, P. Bacci will use appropriate packing to
ensure the machine does is not damaged during shipment and up to delivery to the customer.
The machine will be shipped directly on the truck platform or inside a container, based on the distance
from the place of delivery, on customer requirements and on how long the machine will remain packed.
If the machine is to remain packed for a long time or if shipping involves crossing the sea, machine parts
subject to oxidizing (screws, chains, etc.) will be covered with a protective rust-proof substance).
Anti-humidity salts are placed inside the electrical boards to absorb possible humidity/condensation. All
precautions are taken when placing these salts to avoid contact with metal parts that may become
corroded. Based on the type of shipment, the inside of the electrical cabinet may also be packed with a
barrier bag to keep out humidity.
For load hoisting and handling, it is OBLIGATORY to always consult the respective specifications
contained in this manual.
Upon delivery of the machine, check that the packaging has not been damaged during shipment and that
the supply is conformant to the contract specifications.
If the machine has been damages, immediately notify the carrier and the Bacci technician.
Either wood or metal blocks may be used to ensure machine stability during shipment. These blocks
must all be removed.
For the entire time that the machine remains idle waiting for start-up, we recommend:
• Protecting the machine with polyethylene sheets or tarps to keep dust from covering the
mechanisms and collision-proof covers to avoid possible damage.
• Never leave the machine outdoors or exposed to inclement weather.
• Always check that storage temperatures are within the maximum and minimum temperature
range specified in the technical data and machine performance data.
All operations must be carried out by qualified personnel authorized by P. BACCI S.r.l.
Chap. 4
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4.2.3 Packaging and shipment precautions and tactics

Packaging is designed so that possible stresses or stains owing to transport do not exceed the
admissible values established by specific standards and do not cause permanent deformations or
damage that could negatively affect the performance of the machine or its components.
The machine can be transported using different types of packaging depending on destination and
transport modalities.
INFORMATION!
In the event of damage or lack of certain parts, contact Paolino Bacci Srl to agree upon the
procedures to adopt.
Depending on the characteristics of the machine or its parts, different devices and materials are used to
protect the machine or its parts during transport.
PACKAGING PRECAUTIONS 1 of 2
TYPE DESCRIPTION COMPONENTS
• Nylon protective film is used as a dust-proof cover and
protection against light collisions and scratches of painted
• Structure.
Nylon parts.
protective film • • Control
The film also partly protects the machine from gentle
panels.
atmospheric phenomena and prevents foreign material (dirt)
from depositing on the machine.
• The application of grease on surfaces or machine • Joints.
components aims to protect the components from • Couplings.
Grease
atmospheric agents and prevent accumulation of foreign • Guides.
material on the machine. • Bearings.
• Application of protective rustproof paint on surfaces or
machine components aims to protect components from
atmospheric agents and corrosion phenomena.
• Machine parts subject to rust are covered with protective
paint:
o if the period between shipment and installation is
over 3 days.
o if the machine must be shipped by sea. • Structure
o in winter and in climatic zones where there is high • Screws
Protective
rustproof paint
humidity. • Uncovered
parts
INFORMATION!
Before the first start-up of the machine it is
necessary to clean the different components that
underwent protective treatment for shipment
purposes. Refer to the rustproof paint supplier’s
card for safety information on using masks/shields
and clothing to avoid contact with paint.
Chap. 4
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PACKAGING PRECAUTIONS 2 of 2
TYPE DESCRIPTION COMPONENTS
• Bags of anti-humidity salt are placed inside electrical
switchboards and control panels.
• When the machine is shipped in a container anti-humidity
salt is placed inside the barrier bag. • Electrical
Anti-humidity
boards
salts
INFORMATION! • Barrier bag
Before the first start-up of the machine it is
necessary to remove all bags of anti-humidity salt.
• Wooden crates are normally used to ship the machine or

other disassembled machine parts, equipment or spare
Wooden crates • Miscellaneous
parts of the machine, equipment or material for assembly
purposes.
• Should the machine be shipped inside a container, all the
• All
material in the container is contained inside the barrier
components
Barrier bag bag and is hermetically sealed. The barrier bag aims to
contained in
protect components from atmospheric agents and
the container
corrosion phenomena.
ENVIRONMENTAL INFORMATION!
The disposal of packaging material must be performed in accordance with the current waste
disposal standards of the country where the machine will run.
Chap. 4
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4.3 Preparing the machine for shipment
4.3.1 Disconnecting the electrical cabinet
STEP ACTION DESCRIPTION

• Before working on any machine circuit or component, it is
OBLIGATORY to always verify that there is no residual voltage or
pressure in the systems, making sure that work is carried out safely and
Safety checks that all safety devices are in place and working. Also make sure that all
1 personnel in the vicinity have been warned of the work being carried
out.
Check that all operators are in a safe position and aware of the work
being carried out.
• Danger of bumping into the structure and machine parts. Move

Warnings /
cautiously during inspection work.
Precautions
2
• Danger of slipping, tripping and falling inside the machine.
Move cautiously during work.
• Some electrical connections between the electrical cabinet and the

various machine parts may have been made using cables that are wired
directly onto the components (1) (for ex. inverter) or present on the low
terminal board (2).
• Disconnect the electrical wires checking that all connectors/wires are
numbered. If necessary, mark the rout of the wires.
• Consult the wiring diagram in ANNEX A SYSTEM DIAGRAMS.
Disconnecting 1
2
machine wires
Chap. 4
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4.3.2 Mechanical preparations for transport

• Before working on any machine circuit or component, it is OBLIGATORY to
always verify that there is no residual voltage or pressure in the systems,
making sure that work is carried out safely and that all safety devices are in
Safety checks
place and working. Also make sure that all personnel in the vicinity have
1
been warned of the work being carried out.
Check that all operators are in a safe position and aware of the work being
carried out.
• Danger of bumping into the structure and machine parts. Move

Warnings /
cautiously during inspection work.
Precautions
2
• Danger of slipping, tripping and falling inside the machine. Move
cautiously during work.
• To keep machine parts from moving during transportation, the linear axes
may be blocked into place mechanically.
• Wind a part of the ball screw (1) with a copper sheet (4) to protect it.
• Screw the block (2) on the part of the screw covered by the sheet (4).
Tighten the screws (5) against the surface of the structure (3).
Mechanical
3
block of axes
Chap. 4
- 12/20 -
4.4 Component and load group identification and handling
Machine hoisting and handling equipment that must be provided by the end user customer are:
• N. 1 crane.
• N. 1 lift-truck.
• Polyester hoisting straps.
• 80 mm diameter hoisting pipes. The length must be 500 mm longer than the machine frames.
DANGER!
All hoisting equipment must be chosen based on the weights to be hoisted to keep the loads from falling.
The table below summarized a few types of hoisting methods. The photographs are indicative of the
method to be used to prepare and hook up the hoisting equipment.
Machine hoisting drawings and diagrams may be found in ANNEX B TECHNICAL DIAGRAMS AND
GENERAL INFORMATION.
TYPE OF HANDLING
HOISTING
• Certain structures or the machine body may be hoisted by using a crane (1),
hooked up to the polyester straps (2) and pipes (3) inserted in the special
holes on the machine structures.
• The polyester straps anchored to the pipes may be positioned closet o the
structures or left at a distance of about 400 mm (4) to be able to balance the
movement deriving from the distribution of the machine weight.
Handling using a
crane, hoisting 2
pipes and straps
3
Chap. 4
- 13/20 -
TYPE OF HANDLING
HOISTING
• Some machine structures or the machine body may be hoisted using a crane,
hooked up to the polyester straps (1) wound around the structures.
• Position the straps on the external part of the structures to be hoisted (2),
making sure they will not be crushed or come into contact with edges or
corners that may damage them.
• Rest the structures on wood supports (3) that make it possible to slip off the
polyester straps.
• Some machine structures may be hoisted using a lift-truck. The forks of the lift-
truck (1) must be positioned under the pipes (2) inserted in the special holes
on the machine structure.
2 1
Handling using a lift-

truck and pipes
Chap. 4
- 14/20 -
TYPE OF HANDLING
HOISTING
• The machine’s electrical cabinet (6) has four eyebolts (7) located on the upper
section of the cabinet to allow for hoisting using a specific hoisting device,
such as, for example, a crane (1) and four ropes (2).
• If the cabinet has been packed in a barrier bag (3) for shipping, it may be
handled using a lift-truck (5).
• Once the protective wood crate has been removed (4) the electrical cabinet
may be handled using a crane (1) and four ropes (2) connected to the four
eyebolts (7).
Handling the
electrical cabinet
Chap. 4
- 15/20 -
4.5 Loading, transportation and unloading
The procedure below describes the main recommendations for loading, transporting and unloading the
machine.
STEPS DESCRIPTION
• Loading and unloading must be carried out only by specialized and authorized
Safety checks personnel.
• Mark off the loading and unloading area and warn exposed persons of the
operations underway.
• The machine is shipped in more than one piece, each of which is anchored
using wood beams, straps or similar means, to store and fasten the load.
Loading • The load is always protected against inclement weather conditions using PVC
sheets.
• Particular care must be taken when dealing with over-sized loads.

• The maximum height permitted for loads hauled by road is 4 meters,
considering the height of the vehicle and the load together. Some loads are
hauled on special trucks with a lowered platform in order to stay within the 4
meter height limit.
Transportation • Take special care of over-sized machines shipped in OPEN TOP type
containers. In these cases, Paolino Bacci S.r.l. will transport the load up to the
ship. Unless otherwise agreed upon, the customer must organize and provide
for road haulage from the port of destination to the installation site, choosing
means of transport suited to the load to be transported.
• Inspect the load visually and make sure that the PVC sheets are whole and not
cut or torn.
• After having removed the PVC sheets, make sure that the load has not moved;
Checks on the straps must be in place and pulled taut and the wood slats must be well
arrival anchored to the load.
• If the machine has been damaged, immediately inform the carrier and Paolino
Bacci S.r.l technical personnel.
• Always upload the smallest and most easily reached items first.
• Unload one load unit at a time.
• Find the hook up points of the load units and always fasten the hoisting
Unloading equipment before removing the straps and slats that block the load.
• Start hoisting gradually, moving the load without bumping against the transport
vehicle.
Chap. 4
- 16/20 -
4.6 Installation site requirements

The site where the machine is to be positioned must meet certain requirements. The buyer is
responsible for preparing the machine’s site of installation.
4.6.1 Floor specifications
The site where the machine is to be positioned must meet certain requirements. The buyer is
responsible for preparing the machine’s site of installation.
For machine installation, an industrial type floor made of plain concrete (or a similar material), at least 20
cm thick, will suffice.
The surface must be flat (maximum admissible inclination of 2:1000).
If the concrete is reinforced with a steel grid, the grid must be deep enough under the surface of the
floor, seeing as the machine is installed using anchoring bolts that reach a depth of 15 cm.
Ditches for the removal of dust and chips must be at a distance of at least 10 cm from the machine’s
resting feet.
TYPE DESCRIPTION
Type of floor Industrial cement
Floor thickness At least 20 cm
Surface planarity 2:1000
Distance from the surface of reinforcement > 15 cm
grid
Distance of ditches from resting feet > 10 cm
4.6.2 Ambient data
Proper machine efficiency depends on the following ambient conditions.
CRITERIA SPECIFICATION
Temperature Between +5°C and 47°C
Relative humidity Between 10% and 90%
Chap. 4
- 17/20 -
4.6.3 Illumination and aeration

Provide for natural or artificial lighting sufficient to safeguard operator health and safety.
Make sure that the environment is well aired to safeguard operator health.
4.6.4 Dust removal system
The vacuum system is not provided with the machine. For correct and safe machine use, the machine
must be connected to a dust removal system that meets the specifications provided in ANNEX B
TECHNICAL DIAGRAMS AND GENERAL INFORMATION.
4.7 Assembly
The machine is assembled by Bacci technicians, as assembly may present risks for un-specialized
personnel and requires specific and unique manufacturer know-how.
The information provided in this manual provides a minimal description of the tasks to be carried out.
During cleaning and installation, designated personnel must use all appropriate personal protective
equipment (overalls, gloves, glasses, etc.) and must be familiar with machine access procedures and
residual risks associated to the tasks being carried out.
Personnel must be informed of the safety procedures and risks present in the customer’s plant.
4.7.1 Anchoring the machine
To position the machine, proceed as described below.

• Before working on any machine circuit or component, it is OBLIGATORY to
always verify that there is no residual voltage or pressure in the systems,
making sure that work is carried out safely and that all safety devices are in
Safety checks
place and working. Also make sure that all personnel in the vicinity have
1
been warned of the work being carried out.
Check that all operators are in a safe position and aware of the work being
carried out.
Warnings / • Danger of bumping into the machine structure or parts. Move

Precautions cautiously during inspection work.
2
• Danger of slipping, tripping and falling inside the machine. Move
cautiously during work.
• Position the machine in conformity with the measurements shown in the
Positioning
3 diagram contained in ANNEX B TECHNICAL DIAGRAMS AND GENERAL
diagram
INFORMATION.
Chap. 4
- 18/20 -
• Measure the levelness of the X axis by placing a precision level halfway
Levelness along the length of the X axis ball screw or halfway along the length of one
4
check of the X axis linear guides.
• Turn the four adjustment screws (2) at the corners of the machine body.
Turn the screws 1/4 turn at a time.
5 Adjustment
Levelness • Measure the levelness of the Y axis by placing a precision level on the
6
check resting plate.
• Turn the four adjustment screws (2) at the corners of the machine body.
Turn the screws 1/4 turn at a time.
7 Adjustment
• Act on the adjustment screws (2) to rest all the other plates on the ground
Fastening the uniformly. Always turn the pair of screws at the opposite ends by 1/4 of a
8
plates turn at a time.
• Check levelness along the X axis and the Y axis.

9 Leveling
Tightening the • Block the adjustments screws using the lock-nuts (4).
10
screws
• Use the anchoring holes (1) as a template to drill the anchoring holes in the
Inserting
11 ground for the anchor screws.
anchor screws
• Anchor the machine body to the ground using the anchoring bolts (3).
12 Anchoring
Chap. 4
- 19/20 -
4.7.2 Removing safety guards and blocks used for transportation
Once the machine has been anchored to the ground, remove all the safety guards and blocks used
during transportation.
4.8 Connection to power supplies
The wires and cables between the machine and the electrical cabinet are removed for ease of
transportation.
• Connect the machine cables and wires to the electrical cabinet following the wiring diagram.
• The position of the electrical power supply connection points is shown in ANNEX B TECHNICAL
DIAGRAMS AND GENERAL INFORMATION.
• For electrical and pneumatic connection information, please consult the technical data.
DANGER!
The customer shall be liable for any damage deriving from the machine being connected to electrical
and/or compressed air power supplies that are not conformant to the specifications provided here
following..
Chap. 4
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CHAPTER 5 – Controls and use
CHAPTER
5 Controls and use
Chap. 5
- 1/48 -
INDEX
5 Controls and use ......................................................................................................... 1

5.1 Location of machine control panels .......................................................................................................3
5.1.1 Main switch ................................................................................................................................................ 5
5.1.2 Main pushbutton panel ............................................................................................................................... 6
5.1.3 Portable pushbutton panel ......................................................................................................................... 9
5.1.4 Table pushbutton panel ............................................................................................................................ 11
5.1.5 Bench control foot pedal...........................................................................................................................12
5.2 Operating procedures ............................................................................................................................13
5.3 Machine turn on and start up procedures ............................................................................................13
5.3.1 Start-up procedure – preliminary operations ............................................................................................ 14
5.3.2 Start-up procedure – Turning on the machine .......................................................................................... 16
5.3.3 Start-up procedure – Zeroing ................................................................................................................... 18
5.3.4 Spindle pre-heating .................................................................................................................................. 20
5.4 Machine turn off procedure ...................................................................................................................21
5.4.1 Machine turn off procedure for more than two hours ................................................................................ 22
5.5 Machine stop and re-start ......................................................................................................................23
5.5.1 Stop and re-start procedure after an EMERGENCY ................................................................................ 24
5.5.2 Stop and re-start procedure after working stop - STOP ........................................................................... 25
5.5.3 Stop and re-start procedure after working stop - RESET ......................................................................... 26
5.5.4 Machine stop during machining ................................................................................................................ 27
5.6 Working procedures ...............................................................................................................................27
5.6.1 Operating modes ...................................................................................................................................... 27
5.6.2 HOLD-TO-RUN movements (portable control)......................................................................................... 28
5.6.3 SINGLE PITCH loading/unloading (work cycle) ....................................................................................... 29
5.6.4 TANDEM processing cycle.......................................................................................................................31
5.7 Equipping the machine ..........................................................................................................................32
5.7.1 Tools ........................................................................................................................................................ 32
5.7.2 Machine tool diameter and weight ............................................................................................................ 33
5.7.3 Sharpening machine tools ........................................................................................................................ 33
5.7.4 Machine tool assembly information .......................................................................................................... 34
5.7.5 Balancing machine tools .......................................................................................................................... 35
5.7.6 Cleaning machine tools ............................................................................................................................ 36
5.7.7 Loading and presetting tools .................................................................................................................... 37
5.8 Setup of piece support devices and presser clamps..........................................................................39
5.8.1 Adjusting the pressers .............................................................................................................................. 39
5.8.2 Setup sequence ....................................................................................................................................... 40
5.8.3 Checking proper piece blocking ............................................................................................................... 40
5.8.4 Machining check ...................................................................................................................................... 40
5.9 TANDEM processing cycle setup..........................................................................................................41
5.10 Programming...........................................................................................................................................41
5.11 Overview of the main PITAGORA functions ........................................................................................42
5.12 Telephone troubleshooting service ......................................................................................................45
5.12.1 Intervention procedure ............................................................................................................................. 45
5.12.2 Connecting the machine for teleservice ................................................................................................... 46
Chap. 5
- 2/48 -
5.1 Location of machine control panels

The pushbutton panels on the machine and the control panel may be used to modify the various
machine work parameters and/or control the machine. The controls located on the various machine
control panels are described in this chapter.
The machine must be run and operated by qualified and authorized personnel who have read and fully
understood the instructions provided in this manual and who are familiar with the machine’s safety
devices.
In the event of serious machine malfunctions or unidentifiable malfunctions, stop the machine and wait
for qualified technicians to intervene.
CONTROL LOCATION
Main switch Located on the door of the
electrical cabinet.
Main pushbutton panel Located on the door of the

electrical cabinet.
Industrial PC keyboard Located on the door of the

electrical cabinet.
Chap. 5
- 3/48 -
CONTROL LOCATION
Portable pushbutton panel Located inside the machine’s all-
around safety enclosure.
It is connected to the electrical

board by a cable that renders the
panel portable.
Table pushbutton panel Located near the

loading/unloading area.
Bench pedal Located near the

loading/unloading area.
Chap. 5
- 4/48 -
5.1.1 Main switch
MAIN SWITCH
POS. CONTROL DESCRIPTION

Two-position main switch (0 – 1)
Turn the switch to turn the machine on and off:
1 Main switch • In the "0" position, the machine is off.

• In the "1" the machine is on. The electrical cabinet is
powered by the electrical grid.
Chap. 5
- 5/48 -
5.1.2 Main pushbutton panel
CONTROLS ON THE MAIN PUSHBUTTON PANEL
1 2 3 4
When the pilot light is on, the machine is connected.

“Grid connected” pilot
1
light
When the pilot light is off, the machine is disconnected.
Backlit control
When the pushbutton is lit, the vacuum pump is on.
pushbutton: "LH bench
2 vacuum pump on/off"
Press the pushbutton to turn off the pump and enable blocking
the pieces using the clamps.
(WHERE PRESENT)
Backlit control
pushbutton: "RH bench When the pushbutton is lit, the vacuum pump is on.
vacuum pump on/off"
3
Press the pushbutton to turn off the pump and enable blocking
(WHERE PRESENT) the pieces using the clamps.
Backlit control pushbutton:

"Stop vacuum pumps" When the pushbutton is lit, the vacuum pumps are on.
4 Press the pushbutton to turn off the pumps and enable blocking
(WHERE PRESENT) the pieces using the clamps.
NOTE: controls 2, 3 and 4, in some machine configurations may have different functions
compared to those described in the table. In this case, please refer to the information described
in ANNEX B - TECHNICAL DRAWINGS AND GENERAL INFORMATION, for identifying specific
functions.
Chap. 5
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5 6
7 8
8
Use the key selector switch to select either manual or automatic

operating mode.
The 2 operating modes differ in terms of degree of operating

safety. Manual operating mode is not as safe as automatic
Key “Automatic / Manual“ operating mode. Only the machine operator may use this selector
operating mode selector switch.
5 Remove and store the key in a safe place to prevent use by
switch
unauthorized personnel.
Select the “HOLD TO RUN” mode only for tasks that must be
carried out on board the machine, such as, for example,
equipping the machine, machining trial runs and maintenance,
etc.
Select “Automatic” mode to carry out normal piece machining.
.
When an axis has gone into over-stroke, this pushbutton returns
“Return from over-stroke” the axis to the work range.
6
pushbutton.
Only the machine operator may use this pushbutton.
Press this button to stop the axes and spindles. It does not turn
off the machine.
7 Stop work pushbutton
Restart the cycle by pressing the automatic Start Cycle button.
“Turn on auxiliaries” Use this control to turn on the auxiliaries. Power supplies
8
control pushbutton (compressed air and electricity) must be present.
Chap. 5
- 7/48 -
9 10 11 12
9 RESET pushbutton Press the RESET button to reset the machine after a stop.
"Start automatic cycle"

10 Press this pushbutton to start the machining program.
control pushbutton
11 Pushbutton not present
Stops the machine in emergency mode and turns off the

machine.
Disconnects power to the axes and spindles 1).

Emergency stop
12 The pushbutton has a mechanical block that keeps it in position;
pushbutton
turn it to the left to release.
Use the emergency pushbutton in case of imminent danger for

the operator.
Chap. 5
- 8/48 -
5.1.3 Portable pushbutton panel
CONTROLS ON THE PORTABLE PUSHBUTTON PANEL
4
2

When the pilot light is on, the pushbutton panel is enabled.
“Pushbutton panel The panel may be enabled using the Soft key
1
enabled” pilot light
When the pilot light is off, the pushbutton panel is disabled.
The potentiometer may be used to vary the speed of the axes
and the spindles between 0 and 100%.
2 "Override" potentiometer
The potentiometer is enabled in both Manual and Automatic
modes.
Press this pushbutton to confirm the operations controller using

the portable pushbutton panel.
When the pushbutton is released, the operation is terminated.
Collision hazard.
3 Life Man Switch For all manual movements: Keep an eye on the orientation of the
axes.
The speed of all the movements is reduced to a maximum of 2

m/min.
Rotation of the electric spindle in manual mode is not permitted.
Press this control to stop the axes and spindles.
4 "Stop" Pushbutton
Pressing the STOP control does not turn off the machine.
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CONTROLS ON THE PORTABLE PUSHBUTTON PANEL
6
7

Press this control to move the axis as described on the control
“Axis movement” control
5 itself, either forwards or backwards. Only one axis may be moved
pushbutton
at a time, with a hold-to-run type action.
Tool change control Press this control to rotate the magazine position forwards.
6
pushbutton (optional)
“Axis position Use this control in “Programming for self-learning” mode.
7 digitalization” control To be used to zero the axes in JOG mode or to BLOCK/UNLOCK
pushbutton execution of programs in MEM mode.
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5.1.4 Table pushbutton panel
CONTROLS IN THE TABLE PUSHBUTTON PANEL
Stops the machine in emergency mode and turns off the

machine.
Disconnects power from axes and spindles 1).

Emergency Stop
3 The pushbutton has a mechanical block that keeps it in position;
Pushbutton
turn it to the left to release.
Use the emergency pushbutton only in the event of

imminent danger for the operator.
Free for future installations.

2 Not present
This command select the opening mode of the sliding doors.

3 “Door” command button
Manual mode: open and close the loading sliding doors.
Automatic mode: close the loading sliding doors.
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5.1.5 Bench control foot pedal
BENCH CONTROL FOOT PEDAL
DESCRIPTION OF CONTROLS
Use this control to select how the piece is blocked.
• Manual mode:
The piece is blocked:
• For machines with TGV tables with clamps:

The piece is blocked at low pressure.
• For machines with TGV tables, vacuum surface or suction

cup system:
The piece is vacuum-blocked.
• Pressing the pedal again releases the piece.
Note: The loading door is open.
1 “Block piece” pedal • Automatic mode:

The piece is blocked:
• For machines with TGV tables with clamps:

The piece is blocked at low pressure.
• For machines with TGV tables, vacuum surface or suction

cup system:
The piece is vacuum-blocked.
• Pressing the pedal again releases the piece.

The automatic release piece control automatically
releases the piece at the end of the cycle.
• Note: The loading door is open.
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5.2 Operating procedures

The sections that follow describe the operator tasks required for correct machine operation.
We recommend designated personnel read and fully comprehend the instruction manual, particularly as
regarding operating instructions and safety recommendations.
5.3 Machine turn on and start up procedures

First machine start-up must be carried out by our technical assistance personnel or by maintenance
personnel duly trained and qualified to carry out the first start-up procedure.
The first start-up procedure may be carried out first as an empty run, without loading pieces into the
machine, to check the correct functioning of the machine units and, subsequently, loading pieces to be
machined to check that the machine and the piece gripping devices are functioning properly.
Machine production depends on customer choices (with the exception of the limits specified in this
manual); each type of production needs to be prepared based on the characteristics of the final product.
The sections that follow describe the procedures to be carried out to turn on, start-up and run the
machine.
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5.3.1 Start-up procedure – preliminary operations

The following safety checks must be performed before beginning the start-
up procedure:
Safety checks
• It is OBLIGATORY that the machine be run by only one authorized
operator; therefore, simultaneous use of the machine by two or
more persons is FORBIDDEN.
• If the machine has been stopped for maintenance purposes, it is
OBLIGATORY to check that the maintenance has been completed
1
and that all machine safety devices are in place and functional (for
example, guards, emergency devices, etc.) and that machine
conditions allow for safe start-up.
• It is OBLIGATORY to check that all safety devices are properly
assembled on the machine and fully functional.
It is OBLIGATORY to check that all persons exposed to risks due to the
start-up of mechanical parts are outside the machine safety guards, in a
safe position and have been warned of imminent machine start-up.
Warnings /
Precautions • Danger of colliding with the machine structure or components.
Move cautiously during machine start-up.
2
• Danger of slipping, tripping and falling near the machine
control stations. Move cautiously during work.
Periodic • It is OBLIGATORY to always check proper functioning of the safety

checks of guards and devices on the machine. For this purpose, carry out all the
safety guards checks described in the “Safety Information” chapter.
3
and devices • It is FORBIDDEN to use the machine if the safety guards and devices
have been removed, are malfunctioning or have been disabled even
temporarily.
• Open the main cut-off valve (1): by pressing and turning the knob
clockwise.
Opening the
4
cut-off valve
1 1
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Check the pneumatic supply air pressure.
Initial regulation of pressure gauges:

Check • Check that the pressure gauge for the balancing cylinders (2) shows a
pneumatic air working pressure of 6 bar.
5
supply
If the pressure shown is not the working pressure, use the pressure
pressure.
regulator for the balancing cylinders (1) to increase or decrease the
pressure as required.
• Check that the pressure gauge for the doors/piece clamps (5) shows a
working pressure of 6 bar.
If the pressure shown is not the working pressure, use the

pressure regulator for the doors/piece clamps (1) to increase or
decrease the pressure as required.
• Check that the spindle cooling pressure gauge shows a working

pressure of 6 bar.
If the pressure shown is not the working pressure, use the

pressure regulator for the spindle cooler (1) to increase or decrease the
pressure as required.
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5.3.2 Start-up procedure – Turning on the machine

up procedure:
Safety checks
1
safe position and have been warned of imminent machine start-up
Warnings /
2
Periodic • It is OBLIGATORY to always check proper functioning of the safety

checks of guards and devices on the machine. For this purpose, carry out all the
safety guards checks described in the “Safety Information” chapter.
3
and devices. • It is FORBIDDEN to use the machine if the safety guards and devices
have been removed, are malfunctioning or have been disabled even
temporarily.
• Turn the main switch to "I".
Open knife
4
switch
Wait for the CN operating system to start up.

5 Start system The login dialog box for password entry will appear on the screen.
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Release any Emergency pushbuttons that have been pressed by pressing
and turning the button to the left.
Release
6 emergency
pushbuttons
Press the "Reset" button.
7 RESET
• Press the “Turn on Auxiliaries" pushbutton (8).

• The “Grid connected” pilot light (1) turns on, indicating that the machine
is powered.
Turn on
8
auxiliaries
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5.3.3 Start-up procedure – Zeroing

up procedure:
Safety checks
1
safe position and have been warned of imminent machine start-up
Warnings /
2
• It is OBLIGATORY to always check proper functioning of the safety

Periodic guards and devices on the machine. For this purpose, carry out all the
checks of checks described in the “Safety Information” chapter.
3 safety guards • It is FORBIDDEN to use the machine if the safety guards and devices
and devices. have been removed, are malfunctioning or have been disabled even
temporarily.
Enable the portable control panel from the main menu.

• The softkey changes color.
The pilot light (1) on the portable control panel turns on.
Enable
4 portable
control
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• Turn the "Overdrive" potentiometer (2) gradually to "0%"
Zero
5
potentiometer
Zero all the axes using the control panel. From the Main Menu, press the
ZEROING Softkey F.
6 Zero axes
Turn the "Overdrive" potentiometer gradually to 100%.
Set
7
potentiometer
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5.3.4 Spindle pre-heating
During the first daily start-up, and any time the spindles have cooled to room temperature, all the
spindles must first run through a short heating cycle, to allow the bearings to gradually reach a uniform
working temperature.
For this purpose, a program must be created in which all the spindles are used as follows:
SPINDLE PRE-HEATING PROCEDURE 1 of 1

STEP ROTATION SPEED CYCLE TIME
1 50% max speed (12,000 1/min) 5 min
2 75% max speed (18,000 1/min) 3 min
3 100% max speed (24,000 1/min) 3 min
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5.4 Machine turn off procedure

To turn off the machine, proceed as described following.

Press the "Reset" button.
Machine
1 Reset
Press one of the Emergency pushbuttons located on the pushbutton panels.
Emergency
2
Pushbutton
• Exit the submenus of the interface panel and return to the main
3 Exit submenus page.
Turn off the Windows operating system:

• Click on START
• Click on CLOSE SESSION
Turn off
4 • Click on STOP SYSTEM
windows
• Click on OK
The following message will appear: “You may now turn off the machine.”
Turn the main switch to "0"
Cut-off power
to the
4 machine.
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5.4.1 Machine turn off procedure for more than two hours
For machine stoppages longer than 2 hours, follow the procedure below.

Turn off the main cut-off valve (turn the knob counter-clockwise) and lock it.
Cut-off The pneumatic system is disconnected from the pneumatic supply network.
compressed The filters discharge any impurities.
air supply
DANGER!
Safety warning
2 The balancing cylinders remain pressurized even after the main switch has
been tagged out.
• Do not tamper with the relative pneumatic pipes to avoid sudden
machine movements.
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5.5 Machine stop and re-start

The paragraphs below describe the procedures to be followed to stop the machine and interrupt or cut-
off power supplies.
In fact, there are three different types of machine stops that the user may execute to stop the machine
running.
• The “Emergency” stop is carried out in the event it becomes necessary to immediately block the
machine due to a risk or unforeseen event; the program being run stops immediately and all
movements are slowed down at the maximum deceleration possible. Electric power is cut-off and the
auxiliaries turn off.
• The working "Stop" is used to stop the program being run without fully stopping all machine
functions. This kind of stop is executed by pressing the “STOP” button on the main panel; the
program being run stops immediately and all movements are slowed down at the deceleration set in
the software parameters. Electric power is not cut-off. The auxiliaries remain turned on.
• The “Reset” stop is used to stop a machining cycle and stop the program by pressing the “Reset”
pushbutton on the main panel or the “Reset” key in the lower right hand corner of the monitor. We
recommend executing this stop only during cycle standby moment.
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5.5.1 Stop and re-start procedure after an EMERGENCY
In the event of a sudden machine stop, be it intentional or accidental, correct function re-start depends
on how the machine has been stopped.
Proceed as described following.

• Before using the machine, all persons involved must be familiar with the
location and use of all the emergency pushbuttons on the machine shown in
the pictures.
Press the
emergency
1 pushbutton
INFORMATION!
Pressing an emergency pushbutton (12) stops the machine in emergency mode
and transmits the stop signal. Pressing an emergency pushbutton also cuts off
power to the axes and spindles.
To re-start the machine:

• Remove the cause for the machine stop.
• Release the "Emergency" pushbutton (12)
Turn the pushbutton to the left.
• Press the "Reset" key (9)
Restart
2
procedure
Press the "Turn on Auxiliaries" pushbutton (8)

The "Grid connected" pilot light (1) turns on.
Turn on
3
auxiliaries
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• If a person is in danger, press the emergency stop pushbutton on any control

panel.
Activating the • The emergency stop is a safety stop and has priority over all other controls; it
4
command is not synchronized with the forward feed of the machined product, which may
therefore become jammed in one or more points in the machine subsequent
to the stop.
5.5.2 Stop and re-start procedure after working stop - STOP


Press the Before using the machine, all persons involved must be familiar with the
STOP location and use of all the STOP pushbuttons on the machine shown in the
1 pushbutton pictures.
To re-start the machine after a machine STOP:

• Remove the cause for the machine stop
• Press the "Reset" key (9).
Re-start
2
procedure
Press the “Start automatic cycle” pushbutton (10)
3 Start cycle
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5.5.3 Stop and re-start procedure after working stop - RESET


Before using the machine, all persons involved must be familiar with the
Press the
location and use of all the RESET pushbuttons on the machine shown in the
RESET
pictures.
1 pushbutton
To re-start the machine after a machine STOP:

• Remove the cause for the machine stop
• Press the "Reset" key (9).
Re-start
2
procedure
Press the “Start automatic cycle” pushbutton (10)
3 Start cycle
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5.5.4 Machine stop during machining
If the machine has been stopped during a machining cycle, the operator must remove the spindle from
the piece.
NOTE
Safety
warning
DANGER!
Danger of collision between the spindle and the piece.
5.6 Working procedures

The sections that follow describe the operator tasks required for correct machine operation.
We recommend the instruction manual be read and fully comprehended before machine use, especially
as regards operating procedures and safety regulations.
5.6.1 Operating modes

The machine may be run in four different modes.
HOLD-TO-RUN movement (portable control)

Machine movements controlled exclusively by skilled and authorized personnel using the portable control
located inside the safety enclosure.
SINGLE-STEP, loading/unloading (processing cycle)

Loading/unloading of the materials, with the operator standing in front of the machine, manually loading
and unloading the piece(s) on/from the support devices located on the table. Once the piece is placed, it
is locked by pressing the pedal button; then the loading operation is confirmed, and the machine brings
the piece in working position (inside the machine, in the machining heads area).
The closing of the clamps during the stage when the operator interacts with the support device, is
performed at reduced pressure. The pressure is then increased, after confirmation of the end of loading,
by pressing the specific button.
At the end of processing, the piece is automatically taken outside the machine and the operator manually
removes it from the support devices; then a new piece is loaded and another processing cycle is started.
TANDEM processing cycle

The processing occurs with the piece supported by both support devices (Y1 and Y2 axes) that move
synchronously. The tandem processing requires a machine setup operation by the maintenance
technician, who removes the central guard located between the two axes Y1 and Y2, and enables the
tandem processing in the software, which allows synchronous advancing of axes Y1 and Y2. At the end
of tandem processing, the maintenance technician must perform the setup for SINGLE-STEP,
loading/unloading processing. To do this, it is mandatory to reassemble the central guard and disable the
tandem processing in the software. The processing cycle occurs in the manner described in the
SINGLE-STEP, loading/unloading (processing cycle).
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5.6.2 HOLD-TO-RUN movements (portable control)
The machine may be used in “HOLD TO RUN” mode only by the operator designated to
run the machine.
• The operator must use the “HOLD TO RUN” mode only for operations that must be
supervised closely.
• Insert the key in the Operating mode selector switch. Turn the selector to “HOLD
TO RUN” mode. Remove the key and store it in a safe place.
• The operator enters the enclosure while the machine is running. All machine
movements are slowed down to a maximum speed of 2 m/min.
• To enable any movement, the operator must press the specific command
pushbutton on the portable control and the “Life man” pushbutton, keeping it
pressed until the position required is reached. When the pushbutton is released,
the movement stops.
• Manual spindle rotation is not enabled in this mode.
NOTE
DANGER!
Safety warning Crushing hazard.
The machining head moves in every direction.
• Hold the portable control in one hand.
• Rest the other hand on the STOP pushbutton.
• Be careful of moving machine parts.
NOTE
DANGER!
Safety warning Danger of flying dust, chips and machining scraps.
• All machining scraps fly off the tool.
• The direction in which scraps fly off the tool may change suddenly and quickly.
• Use the following personal protective equipment: ,
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OPERATIONS IN MANUAL MODE

USER DESCRIPTION
The following tasks must be carried out with the machine in manual
mode:
• Machine equipping
• Machine cleaning
Maintenance personnel • Machine maintenance
INFORMATION!
Any other operation is forbidden in manual mode.
5.6.3 SINGLE PITCH loading/unloading (work cycle)
The machine must be used by the operator or maintenance technician for normal
machining of materials.
STEP DESCRIPTION
1 Load the piece program.
Press the “Start cycle” pushbutton.
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STEP DESCRIPTION
Working cycle execution (CNC program).
− Manual loading of the piece.

− Low-pressure locking of the piece through the clamps, performed by the operator
by means of the foot control.
− The operator issues a CYCLE START command.
− The machine automatically closes the door. Once the door is closed, the clamps
lock the piece at high pressure.
− Programmed operation sequence.
− Processing stop and retraction of piece supports.
− Door opening, to allow manual unloading of the processed piece. Depending on
the configuration selected in the control software, the pressers may open
automatically, when the support devices are positioned, or the opening must be
carried out by the operator via the pedal command.
− Manual loading of the next workpiece and repetition of the working cycle.
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5.6.4 TANDEM processing cycle
The machine must be used by the operator or machine maintenance technician, for the
normal processing procedures of the materials.
STAGE DESCRIPTION
Perform machine setup, by following the operations described in section “TANDEM

1
processing cycle setup”.
For performing the processing cycle (CNC program) follow the instructions described in
2 previous section “5.6.3 - SINGLE STEP loading/unloading (processing cycle)”.
At the end of TANDEM processing, the machine setup must be performed, reassembling
3 the central protection of Y1-Y2 axes and selecting the processing parameters in the
control software.
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5.7 Equipping the machine
Only the operator in charge of running the machine may carry out the tasks described in this chapter.
This section contains all the information regarding machine equipping.
This chapter is divided into two parts. The first part deals with the tool, including safety
recommendations, tool choice, maintenance and presetting. The section part deals with how to block the
piece.
5.7.1 Tools
MAINTENANCE NOTE
Machine
maintenance
information INFORMATION!
The tools to be installed on the machine must comply with the EN 847-1:1997
Directive.
STEP DESCRIPTION
Check the following parameters/data on the tool:
• Tool marking
• Manufacturer name
• Max number of revolutions
• Measurements: diameter, length...
• Tools must be marked.
• Work cycles
INFORMATION!
Tools must be marked and must comply with European Community directives. Check
the data on the information plate (1).
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NOTE
DANGER!
Cutting hazard
Tool cutting edges are sharp and may cause:
Safety warning • Cutting injuries
• Puncture injuries.
Handle tools with extreme care.
Use the following personal protective equipment (PPE): metal mesh gloves , when
replacing and handling tools.
5.7.2 Machine tool diameter and weight
Use only tools that have the diameters and weights shown in the table below.
Coupling Max diameter Max tool diameter Max tool weight

Rotation speed (rpm)
size tool shaft (mm) (mm) (kg)
6000 / 9000 150 10
9000 / 12000 130 7
ER40 25
12000 / 15000 110 5
15000 / 18000 80 5
6000 / 9000 140 4
9000 / 12000 130 4
ER32 20
12000 / 15000 110 2.5
15000 / 18000 80 2.5
5.7.3 Sharpening machine tools
MAINTENANCE NOTE
Machine
maintenance
information INFORMATION!
Tools must always be sharp to reduce cutting stress and spindle working temperature.
The heat generated by the spindle itself may overheat the bearings and bearing
lubricant. Overheated lubricant is less efficient and reduces spindle bearing service life.
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5.7.4 Machine tool assembly information
MAINTENANCE NOTE
INFORMATION!
Use only spacers that correspond to the diagram below:
Machine
maintenance
information
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5.7.5 Balancing machine tools
Tools, tool holders and any spacers used must be dynamically balanced in G1.
MAINTENANCE NOTE
INFORMATION!
Rebalance the tool and tool holder every time the tool is sharpened.
Machine
maintenance
Improper tool balancing may lead to:
information
• The tool breaking,
• The tool coming off the spindle.
Balance the tools and tool holder in G1.

Rebalance the tools each time they are sharpened, in G1.
NOTE
DANGER!
Danger of flying tool parts.
Safety warning
Use the following personal protective equipment (PPE): metal mesh gloves , when
replacing and handling tools.
Use the following personal protective equipment (PPE): safety glasses when
sharpening tools.
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5.7.6 Cleaning machine tools
G Tools, tool holders and any spacers used must be dynamically balanced in G1.
MAINTENANCE NOTE
INFORMATION!
Keep the following components rigorously clean:
• Tapers
• Shafts
• Tool gripping clamps
DANGER!
Machine
Danger of the tool holder group breaking.
maintenance
information
The presence of dust deposits on the tool stem may lead to:
• Tool misalignment
• The tool being blocked poorly.
If the operator tightens the clamp ring nut too apply excessive torque, the shaft or tool
holder thread may be damaged.
Clean tools accurately.

Do not tighten the ring nut with a torque greater than that recommended, depending on
the kind of ring nut and characteristics of the electrospindle.
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5.7.7 Loading and presetting tools
To preset the tools, proceed as follows.

• Turn the working unit using the manual controls.
Manual pushbutton control: A+ (15) movement pushbutton
A- (16) movement pushbutton
Positioning
1
spindle head 1
The spindle to be equipped is positioned upwards.
Unscrew the blocking ring nut (1).
2 Unscrew ring nut
Select the clamp with the diameter best suited to the tool.
3 Select clamp Insert the clamp in the taper.
Insert the tool in the clamp and, after having positioned the tool in its seat,
4 Insert tool tighten the ring nut.
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• Turn the working unit using the manual controls.
Manual pushbutton control: A+ (15) movement pushbutton
A- (16) movement pushbutton
Reposition the
5
head
The spindle to be equipped is positioned towards the work side.

Using an appropriate tool, measure the length of the tool.
6 Measure the tool
Update Enter the tool length in the software.

7
parameters
Continue with the other spindles on the machining head, starting from point 1
8 above until all the spindles are equipped.
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5.8 Setup of piece support devices and presser clamps
5.8.1 Adjusting the pressers
The presser clamps may be adjusted in two ways:
• In the first case, for example for a 50 mm piece, the clamps may be adjusted so that when they
are closed the minimum space is 45 mm. This prevents the risk of being crushed, as zero stroke
is never reached when there is no piece in the clamps. However, there is a large risk of being
crushed between two pieces, if the machined piece is not removed before another rough piece is
inserted. Moreover, crushing when there is no piece in the machine is against all machine use
logic and is to be considered an extraordinary event.
• In the second case, again using a 50 mm piece as example, the clamps may be adjusted so that
the opening to insert the piece is 55 mm, and the 5 mm of space avoid the risk of inserting fingers.
This method is closer to actual machining requirements but is effective only if the rough pieces
are uniform and if they are positioned with the greatest care possible.
The importance and need to adjust the presses is a well-known fact, it is standard practice in machine
equipping and must be carried out only by the machine maintenance technician.
The risk of being crushed by the pressers is reduced by the measures adopted to attempt to contrast
possible lack of diligence with redundancy:
• Presser adjustment by the maintenance technician during machine equipping.

• The application of two pressure stages during loading/unloading and machining.
NOTE
DANGER!
Safety warning
Danger of the piece or tool parts flying off the machine.
An erroneous piece program or a piece program applied to a piece that is not blocked
properly may cause the tool to break and tool fragments to fly off the machine. Check the
piece program before starting machining.
Once the machine has been equipped, the operator in charge of running the machine must check that
the work cycle is executed as required. Generally, checks carried out in the original conditions are the
best. The only difference with the final cycle is that the operator holds the portable control and reduces
the machining speed using the potentiometer in order to be able to intervene quickly in the event of
programming or equipping errors, etc.
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5.8.2 Setup sequence
The setup sequence varies according to the type of workpiece support device mounted on the table. As
the machine may use support equipment made up by the customer, the customer is required to
adequately instruct the personnel responsible for machine operation about the specific workpiece
support devices used for processing.
5.8.3 Checking proper piece blocking
The counter-profiles are not supplied with the machine.

The following example is provided only for information purposes.
NOTE
DANGER!
Safety warning Danger of the piece or tool parts flying off the machine.
Improper or inadequate blocking may cause:
The piece to fly off
The tool to break and fly off the machine.
Check that the piece is properly blocked before starting the work cycle.
After having fitted and adjusted the blocking devices, including any counter-profile, check that the piece
has been blocked properly. Check that the piece is blocked in every direction in which machining
pressure may be applied.
5.8.4 Machining check
NOTE
DANGER!
Safety warning
Danger of the piece or tool parts flying off the machine.
An erroneous piece program or a piece program applied to a piece that is not blocked
properly may cause the tool to break and tool fragments to fly off the machine.
Check the piece program before starting machining.
Once the machine has been equipped, the operator in charge of running the machine must check that
the work cycle is executed as required. Generally, checks carried out in the original conditions are the
best. The only difference with the final cycle is that the operator holds the portable control and reduces
the machining speed using the potentiometer in order to be able to intervene quickly in the event of
programming or equipping errors, etc.
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5.9 TANDEM processing cycle setup
The processing occurs with the piece supported by both support devices (Y1 and Y2 axes) that move
synchronously.
• The maintenance technician must remove the central guard located between Y1 and Y2 axes,
and enable the tandem processing in the control software, for allowing synchronous
advancement of Y1 and Y2 axis.
• Once the setup procedure is complete, the machine may be started up by following the
instructions described in section “SINGLE STEP loading/unloading (processing cycle)”.
At the end of the TANDEM processing, the maintenance technician must perform the setup for SINGLE-
STEP, loading/unloading processing. To do this, it is mandatory to reassemble the central guard and
disable the tandem processing in the software.
5.10 Programming
The machine is programmed using the PITAGORA software package, which is for programming and to
optimize all Paolino Bacci S.r.l. CNC work centers. Use of this software allows:
• Fast and easy acquisition of CN programs with maximum optimizing in terms of machine yield,
reducing programming time.
• Optimizing of programs generated by normal CAD CAM systems in terms of productivity and best
possible use of machine performance potential.
• Using the technical features of Paolino Bacci S.r.l. work centers, taking advantage of speed,
accelerations and axis power, through the advanced machining path “jerk limitation” and
“smoothing” functions, without compromising machine reliability and long service life.
PITAGORA is a pure and original WINDOWS® software based on OpenGL® graphics and a calculation
motor developed by Paolino Bacci S.r.l.,
The software creates three dimensional, dynamic images for complete collision control and CN programs
which, as they are developed using practical and intelligent tools, may be optimized to obtain maximum
performance in terms of machine yield.
For detailed information regarding the use of the PITAGORA software, please consult the specific
documents provided in ANNEX D OPERATOR INTERFACE SOFTWARE MANUAL.
The following section of the manual illustrates the main features of the PITAGORA software.
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5.11 Overview of the main PITAGORA functions

The zoom function, the possibility of obtaining piece and machine pan views, enlarging them and rotating
them during any step of the program realization process makes it possible to visually measure collisions
and obtains a precise and reliable result.
Collision control is fully automatic and the programmer need only follow the instructions provided by
PITAGORA for error-proof results.
POS. DESCRIPTION
1 Dialogue box to enter machining selection
2 Dialogue box to enter machining
3 Geometric and technological machining data
4 3D animation
5 Automatic collision check
6 Machining time
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2 4
7
9
POS. DESCRIPTION
1 Dialogue box to enter rapid coupling
2 Dialogue box to enter the path and rapid feedrate
3 3D animation
4 Automatic collision check
5 Execution time for rapid coupling
6 Dialogue box to enter ISO program
7 File importing
8 CN code entered
9 Machining time
Chap. 5
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1
2
POS. DESCRIPTION
1 Windows® interface
2 OpenGL® graphic interface
Chap. 5
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5.12 Telephone troubleshooting service

Should the troubleshooting be difficult, it is possible to use the telephone troubleshooting service of the
manufacturer, Paolino Bacci S.r.l.
DANGER!
During the telephone connection, the manufacturer’s technical department may ask the
customer’s personnel to perform various operations on the machine, aimed at resolving the
malfunctioning.
For the safety of people exposed during troubleshooting, it is MANDATORY to observe the
following intervention procedure.
5.12.1 Intervention procedure
STEP A) CALL THE MANUFACTURER’S TECHNICAL SERVICE HOTLINE AND IDENTIFY THE
ISSUE
• Call the manufacturer’s technical service hotline.

• Provide exact indications on machine identification (model and serial number).
• Provide a description of the issue, of current machine state, and of the event(s) that led to the
malfunctioning.
STEP B) ENSURE INTERVENTION SAFETY
• The customer must identify the person in charge for safety during the intervention, and report
his/her name to the manufacturer’s technical service.
• Machine access during troubleshooting must be permitted only to people identified by the person
in charge for customer’s safety. Delimit the intervention area and inform the people nearby.
• The qualification of people assigned to operate the machine during the troubleshooting must be
assessed by the person in charge for customer’s safety, depending on the actions to be taken.
• The person in charge for customer’s safety has the job of coordinating people and activities
during the troubleshooting.
STEP C) CARRY OUT THE INTERVENTION
• The manufacturer’s technical service asks to take an action on the machine.

• The customer’s technician carry out the required operation only after having clearly understood
what is required.
• Once the operation has been performed, the customer’s technician informs the manufacturer’s
technical service.
STEP D) END OF THE INTERVENTION
• The customer’s technician checks that the machine is in full working order, and that all the guards
that were possibly removed for the intervention have been reassembled and reactivated,
informing the manufacturer’s technical service.
• The manufacturer’s technical service closes the intervention.
Chap. 5
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5.12.2 Connecting the machine for teleservice
During telephone service interventions, if necessary, the machine may be connected for teleservice over
a phone call connection (ISDN, ADSL, HDSL). The following page shows a connection logical diagram.
Except as described in the previous section “Intervention procedure”, when performing the intervention
(STEP C) the person in charge for customer’s safety, and also the authorized technical personnel, must
take into account the risk of machine movements, remotely controlled by the technical personnel of the
manufacturer, Paolino Bacci S.r.l.
TELESERVICE CONNECTION
During the normal operation of the machine, the teleservice must be disconnected and deactivated. The
teleservice connection is always initiated following a request made by the customer, and only after
intervention safety and coordination between customer’s personnel and technical personnel of the
manufacturer, Paolino Bacci S.r.l., has been organized.
Chap. 5
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TELESERVICE CONNECTION LOGICAL DIAGRAM
Service INTRANET
BACCI BACCI Linea telefonica, ISDN,
ADSL, HDSL
INTERNET
CLIENTI
PC 1 Cliente A
Connessione Ethernet
PC 2 Cliente INTRANET
Modem
A CLIENTE A
CNC
Macchina A
Connessione Ethernet
CNC PC
Modem
Macchina B CLIENTE B
Linea telefonica, ISDN,

ADSL, HDSL
CNC + PC
(es. WINMEDIA)
Modem
Macchina C
Chap. 5
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Chap. 5
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CHAPTER 6 – Maintenance
CHAPTER
6 Maintenance
Chap. 6
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TWIN Use and maintenance instruction manual
INDEX
6 Maintenance ................................................................................................................ 1
6.1 Maintenance ..............................................................................................................................................3
6.2 Safety instructions....................................................................................................................................4
6.2.1 Other interventions ..................................................................................................................................... 5
6.3 Maintenance timetable .............................................................................................................................6
6.3.1 Ordinary and extraordinary maintenance timetable .................................................................................... 6
6.3.2 Maintenance interval for multi-shift use of the machine.............................................................................. 8
6.4 Greasing and lubrication .........................................................................................................................9
6.4.1 Useable oils and grease ............................................................................................................................. 9
6.4.1.1 Lubricant oil for the pneumatic system (FLR) ....................................................................... 10
6.4.1.1 Oil for the tool holders .......................................................................................................... 11
6.4.1.1 Oil for the centralized lubrication system ..............................................................................12
6.4.1.2 Greases for the centralized greasing system .......................................................................13
6.4.1.3 Greases for mechanical elements/parts (manual lubrication) ............................................... 14
6.4.2 Maintenance of the centralized lubrication system ................................................................................... 15
6.4.2.1 Automatic system check and topping-up .............................................................................. 16
6.4.3 Maintenance of the centralized greasing system ..................................................................................... 18
6.4.3.1 Automatic system check and topping up .............................................................................. 19
6.5 Daily maintenance ..................................................................................................................................22
6.5.1 Cleaning the machine at the end of each work shift ................................................................................. 22
6.5.2 Cleaning the FRL group (Filter - regulator – lubricator) ........................................................................... 23
6.5.3 Cleaning tools and tool holders ................................................................................................................ 24
6.6 Weekly machine maintenance ...............................................................................................................25
6.7 Monthly machine maintenance .............................................................................................................27
6.7.1 Centralized Lubrication of Linear Axes (OIL LUBRICATION)................................................................... 27
6.8 Six-monthly checks and tests ...............................................................................................................28
6.9 Extraordinary maintenance ...................................................................................................................30
6.10 Decommissioning ...................................................................................................................................30
6.11 Dismantling .............................................................................................................................................31
Chap. 6
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6.1 Maintenance
This chapter contains information that is essential to keep the machine in perfect working order. The
machine is designed to reduce maintenance needs to a minimum.
In order to avoid malfunctions or inconveniences, please follow the maintenance instructions provided in
this section.
MAINTENANCE NOTE
INFORMATION!
Machine A machine that is not regularly cleaned may entail risks for the operator's health. Bad
maintenance maintenance causes early wear and increases the probability of failures and
information breakdowns.
Clean the machine regularly with the recommended frequency.

Follow cleaning procedures.
All interventions must conform to the safety guidelines and safety rules must be
rigorously complied with for the operator's integrity.
INFORMATION!
The concept of maintenance is closely linked with that of functionality. Maintenance stands for the series
of operations that must be performed for a product to remain effective and functional and meet the aims
for which it has been designed; product stands for a building, a machine, a system or a road. The
maintenance activity comprises a series of operations, such as tests, repairs, replacements of pieces or
parts of a product etc.
INFORMATION!
Lubrication maintenance operations can either be performed independently by operators, who intervene
during the work shift when a malfunction, such as low oil level, squeaking etc. arises (autonomous
maintenance intervention), or maintenance mechanics (planned maintenance intervention).
INFORMATION!
Before carrying out any maintenance operation which is not described in this manual, or in case you
have doubts on the information provided please contact Paolino Bacci S.r.L..
INFORMATION!
• All planned mechanical and electrical maintenance operations must be correctly carried out
according to the recommended timetable.
• All use and maintenance operations of the main commercial components of the system, which are
not mentioned in this manual, are contained in the suppliers' publications.
Chap. 6
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6.2 Safety instructions
Maintenance may be carried out only by qualified personnel.

Unless otherwise specified, all maintenance is to be carried out with the machine turned off. In
particular, make sure that the main switch (see Chapter 5: Controls and Use) is in the “0” off position and
that all residual air present in the pneumatic system has been vented using the cut-off valve (see
Chapter 5: Turning the machine on and off).
Both the main switch and the cut-off valve are blocked using locks to prevent machine start-up.
NOTE
DANGER!
Electrocution hazard
Safety warning
The machine must be turned off before any maintenance is carried out. Live parts or
pressurized parts may cause very serious injury.
Turn off the machine and cut-off the air supply.
Block the main switch and the cut-off switch with locks.
NOTE
DANGER!
Safety warning Crushing hazard
The balancing cylinders remain pressurized even after the main valve has been cut-off.
Do not tamper with the relative pneumatic tubes to avoid sudden movements of the
machining head.
NOTE
DANGER!
Safety warning Risk of injury and damage to the machine
Never use compressed air to clean the machine. The jet of air may push chips
and dust into the milling unit or under the contacts of the electric components in
the electrical cabinet.
Clean the machine using an industrial vacuum!
NOTE
Safety warning
Chap. 6
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WARNING!
Risk of damage to the machine.
Strict observance of periodic maintenance requirements is extremely important:

all machine components must be checked on a regular basis to prevent
malfunctions.
• Before starting the machine again, make sure that all maintenance interventions have been duly
completed and the start of the machine does not entail any risks for operators and anyone (PES)
being present in the area.
• Immediately after termination of the maintenance intervention, restore and check the safety
devices that were removed during maintenance and repair.
• EXCLUSIVELY use original spare parts. Spare parts that are not original may not be compatible
and damage the machine.
• All interventions must be compatible with and rigorously respect the safety rules on the operator’s
integrity.
6.2.1 Other interventions
If the need for maintenance and repair interventions that are not contained in this manual arises while
you use the machine, you are recommended to address the Technical Support department of Paolino
Bacci S.r.L.
For telephone and fax contact details please refer to Chap 1 "Manufacturer’s Identification and Contact
Details". In your requests of technical support, always mention the machine identification data referred to
in Chap 1 "How to request spare parts"
Keep the machine clean and in order:

• Avoid any possible damage
• Avoid that provisional repairs become permanent
Chap. 6
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6.3 Maintenance timetable
6.3.1 Ordinary and extraordinary maintenance timetable

The table below contains all the machine maintenance requirements and specifies the maintenance
intervals. Maintenance intervals are calculated considering a 5 day work week, each day being made up
of 8 working hours, in normal working conditions. For multi-shift machine use, consult the section
(Maintenance intervals for multi-shift machine use ".
ORDINARY MAINTENANCE TIMETABLE – MECHANICAL MAINTENANCE TECHNICIAN

Personnel Interval – Product
qualification – Frequency in
Machine part / component Mechanical hours
maintenance
technician
1st degree machine cleaning:
• Resting surface 8h
• Micro-switches and cams
• Blowers
FRL unit:
• Check, clean and top up as 8h See table of oils

required
Centralized lubrication system:
8h NLGI-0
• Level control
1000 h NLGI-1
• Visual inspection
1000 h
• Pressure check
2nd degree machine cleaning:
• Electrical cabinet conditioner

40 h
• Electrical board
• Inside the machine and under
the dust guards
Monthly maintenance:
NLGI-0
• Lubricate skids* and guides* 320 h
NLGI-1
• Discharge condensation from
electric cabinet air conditioner
Chap. 6
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Machine part / component Mechanical hours
maintenance
technician
Pneumatic system:
• Visual inspection of tubes, 1000 h

couplings, etc.
Mechanical parts:
• Visual inspection of mechanical

components (guides, skids, 1000 h
bearing screws) and
components subject to wear
(blowers, guards)
*1 skids and guides that are not included in the automatic lubrication system.
ORDINARY MAINTENANCE TIMETABLE – ELECTRICAL / ELECTRONIC MAINTENANCE

TECHNICIAN
Machine part / component Electrical hours
maintenance
technician
Electrical system:
• Visual inspection: cables and 1000 h

connections
• Check safety devices
ORDINARY MAINTENANCE TIMETABLE – MECHANICAL SUPPORT TECHNICIAN

Machine part / component
Mechanical hours
support technician
Pneumatic system:
• Solenoid valve check (heating 2000 h

and binding) and replacement
as required
• FRL unit check and replacement 2000 h
as required
Mechanics:
• Check correct tautness of 2000 h

transmission belts
• Check that mechanical parts are 2000 h
tight (ring nuts, flanges, etc.)
Chap. 6
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ORDINARY MAINTENANCE TIMETABLE – ELECTRICAL / ELECTRONIC MAINTENANCE

TECHNICIAN
Machine part / component
Mechanical hours
support technician
• Electrical cabinet air conditioner
overhaul
10.000 h
Electrical wiring:
• Electrical, electronic and electro-
mechanical components
• Machining head electric
2000 h
manifold check and brush
replacement
• Electrical cabinet air conditioner
fan
Maintenance frequency is shown in h = hours of operation.
6.3.2 Maintenance interval for multi-shift use of the machine
All indications regarding the maintenance intervals refer to use of the machine for one work shift each
day. If the machine operates for more than one daily shift, the maintenance frequency must be increased
accordingly:
• Every 8h of work, that is, at the end of each shift; (every day for a single shift)
• Every 40 of work, that is, every 5 shifts;.(every week for a single shift)
• Every 160 of work, that is, every 20 shifts; (every month for a single shift)
• Every 320 of work, that is, every 40 shifts.(every 2 months for a single shift)
• Every 1000 of work, that is, every 125 shifts.(every 6 months for a single shift)
• Every 2000 of work, that is, every 250 shifts.(every year for a single shift)
• Every 10.000 of work, that is, every 250 shifts.(every 5 years for a single shift)
INFORMATION!
The employer is responsible for providing maintenance personnel with appropriate PPE.
Chap. 6
- 8/32 -
6.4 Greasing and lubrication
6.4.1 Useable oils and grease
MAINTENANCE NOTE
Use only the recommended oils.

Machine
maintenance Other products may be incompatible with the product used by the manufacturer for first
information lubricant top-up.
The use of incompatible oils mixed together or one after the other may create
substances that are damaging for machine operation, thereby compromising machine
safety.
Abide by the following safety recommendations when using lubricants:
• Wear gloves and protective clothing.

• Wear safety glasses.
• Keep lubricants away from food and drink.
• Immediately remove contaminated clothing.
• Wash hands before work breaks and at the end of the work.
• Avoid prolonged contact with eyes and skin.
• Do not allow the product to enter the sewage system and bodies of water. In the event of leakage
into water basins or sewage systems, immediately inform local competent authorities.
• In the event of spills, collect the liquid using absorbent materials (sand, tripoli, acid binder,
universal binder, sawdust).
Chap. 6
- 9/32 -
6.4.1.1 Lubricant oil for the pneumatic system (FLR)

For the FRL pneumatic system (1), use one of the products indicated in the table below or an ISO/UNI F
class or ISO/UNI H class hydraulic oil.
BRAND TYPE OF OIL

AGIP Oso 10
ESSO Nuto H 5
MOBIL Velocite Oil No. 4
Q8 Puccini 4P
TEXACO 300 Oil 5
TOTAL Azolla ZS 15
MAINTENANCE NOTE
INFORMATION!
• Risk of damage to the machine.
Machine
maintenance
information Use only the oils specified above.
Other products may be incompatible with the product used by the manufacturer for first
lubricant top-up.
The use of incompatible oils mixed together or one after the other may create
substances that are damaging for machine operation, thereby compromising machine
safety.
Chap. 6
- 10/32 -
6.4.1.1 Oil for the tool holders

To lubricate the tapered part of the tool holders (1), use only the product specified in the table below.
BRAND TYPE OF LUBRICANT
METAFLUX Spray paste 70-81
Chap. 6
- 11/32 -
6.4.1.1 Oil for the centralized lubrication system

For the centralized lubrication system (1), use oil that has the characteristics specified in the table below.
Use one of the products indicated in the table below or an ISO/UNI F class or ISO/UNI H class hydraulic
oil.
BRAND TYPE OF OIL

MOBIL DTE OIL HEAVY
MOBIL DTE OIL MEDIUM
MOBIL VACTRA OIL N. 2
Chap. 6
- 12/32 -
6.4.1.2 Greases for the centralized greasing system

For the centralized greasing system (1), use grease that has the characteristics specified in the table
below.
TYPE OF GREASE
NLGI-0 (or equivalent)
MAINTENANCE NOTE
Use only grease that is resistant to high pressure, otherwise, if the oil soaps separate
Machine
inside the lubricant grease, they may then solidify and jam up the pneumatic system.
maintenance
information
Use only one of the greases specified above. Other products may be incompatible with
the product used by the manufacturer for initial greasing. Incompatible greases mixed
together or used one after they other may create substances that are damaging for
machine operation, thereby compromising machine safety.
Chap. 6
- 13/32 -
6.4.1.3 Greases for mechanical elements/parts (manual lubrication)

Use one of the products specified in the table below.
TYPE OF GREASE
SKF bearing grease
MAINTENANCE NOTE
Use only grease that is resistant to high pressure, otherwise, if the oil soaps separate
Machine
maintenance
information
Chap. 6
- 14/32 -
6.4.2 Maintenance of the centralized lubrication system

For detailed information regarding the maintenance of the centralized lubrication system, please consult
the specific information contained in ANNEX E OEM DOCUMENTATION.
Chap. 6
- 15/32 -
6.4.2.1 Automatic system check and topping-up
AUTONOMOUS MAINTENANCE TIMETABLE – MONTHLY CLEANING – LUBRICANT LEVEL

CHECK
QUALIFICATION OF
TYPE OF PERSONNEL
MAINTENANCE MACHINE STATE
MAINTENANCE REQUIRED
PERSONNEL
Check Operators 1 (one) MACHINE CUT-OFF
MAINTENANCE MATERIALS AND EQUIPMENT
• lubricant
ACTIVITY
• Before working on any circuit or component, it is OBBLIGATORY to
check for residual voltage or pressure in the systems, making sure to
always work in safe conditions.
• Risk of bumping into the machine structure and parts. Move cautiously
while carrying out maintenance.
Safety checks
• Risk of slipping, tripping and falling on machining scraps.
1 Move cautiously while carrying out maintenance.
• Risk of dust and materials being flung or sucked in.
• In addition to commonly used PPE, based on the maintenance being
carried out also use one of the following: , PVC coveralls;
; , .
Check the lubricant oil level in the tank.
Keep the tank full (electrical minimum level signal). If the oil pump works
2 Check with the tank empty, air may get pumped into the lubrication system; this
may make it difficult to keep the pumping pressure up and may keep the
pump from priming.
Inspect the entire system, including rigid and flexible pipes (replace if
damaged), couplings (must be sealed) and all the bearings (a small
3 Visual inspection amount of lubricant should be visible along the edge of each bearing).
Check that the lubricating pump is working properly.
MAINTENANCE NOTE
Machine INFORMATION!
maintenance • Risk of damage to the machine.
information
It is essential to bleed all the air from the system. Correct pressure readings depend on
the circuit being full of lubricant. Distributors that have air trapped inside them cannot
signal clogged points. To eliminate all the air from the system, follow the bleeding
procedure described in the attached manual.
Chap. 6
- 16/32 -
MAINTENANCE NOTE
information
Use only one of the greases specified above. Other products may be incompatible
with the product used by the manufacturer for initial greasing. Incompatible
greases mixed together or used one after they other may create substances that
are damaging for machine operation, thereby compromising machine safety.
MAINTENANCE NOTE
Machine
maintenance INFORMATION!
information • Risk of damage to the machine.
Check system pressure. Follow the procedure described in the attached manual.
Chap. 6
- 17/32 -
6.4.3 Maintenance of the centralized greasing system

For detailed information regarding the maintenance of the centralized greasing system, please consult
the specific information contained in ANNEX E OEM DOCUMENTATION
NOTE
DANGER!
Safety Risk of the spring flying off
warning
There is a highly loaded spring (1) inside the tank (see plate 2).
Do not open the lubricant tank.
Top up the tank using the coupling (see procedure).
Chap. 6
- 18/32 -
6.4.3.1 Automatic system check and topping up
AUTONOMOUS MAINTENANCE TIMETABLE – MONTHLY CLEANING – LUBRICANT LEVEL

CHECK
QUALIFICATION OF
TYPE OF PERSONNEL
PERSONNEL
Check Operators 1 (one) MACHINE CUT-OFF
MAINTENANCE EQUIPMENT AND MATERIALS
• lubricant
• pneumatic filling pump
ACTIVITY
Safety checks
; , .
Check the lubricant grease level in the tank.
Keep the tank full (electrical minimum level signal). If the pump works with
2 Check the tank empty, air may get pumped into the lubrication system; this may
make it difficult to keep the pumping pressure up and may keep the pump
from priming.
Inspect the entire system, including rigid and flexible pipes (replace if
damaged), couplings (must be sealed) and all the bearings (a small
3 Visual inspection amount of lubricant should be visible along the edge of each bearing).
Check that the lubricating pump is working properly.
MAINTENANCE NOTE
information
It is essential to bleed all the air from the system. Correct pressure readings depend on
the circuit being full of lubricant. Distributors that have air trapped inside them cannot
signal clogged points. To eliminate all the air from the system, follow the bleeding
procedure described in the attached manual.
Chap. 6
- 19/32 -

Use clean lubricant as foreign bodies may clog the pump filter.
Topping up the
4
tank
Connect the pneumatic filling to the centralized system coupling point.
Connect the
5
system
Fill the tank to the “maximum level” mark.
6 Top-up the tank
Chap. 6
- 20/32 -
MAINTENANCE NOTE
INFORMATION!
Machine • Risk of damage to the machine.
maintenance
information Use only grease that is resistant to high pressure, otherwise, if the oil soaps separate
MAINTENANCE NOTE
Machine
maintenance INFORMATION!
information • Risk of damage to the machine.
Check system pressure. Follow the procedure described in the attached manual.
Chap. 6
- 21/32 -
6.5 Daily maintenance
6.5.1 Cleaning the machine at the end of each work shift

• Remove all chips and other machining scraps. Remove chips using a
suitable industrial vacuum.
Remove
1
chips
• Do not clean the machine using compressed air as the machining chips
may penetrate between the movement gears compromising machine
operation.
Clean the
2
machine
When cleaning the machine, wear the following PPE:
Clean the Clean the machine components thoroughly, removing all grease and dirt
3 machine deposits.
components
MAINTENANCE NOTE
information
Do not use compressed air to clean the machine. The jet of air may push chips
and dust inside the dust guards.
Use an industrial vacuum to clean the machine.
Chap. 6
- 22/32 -
6.5.2 Cleaning the FRL group (Filter - regulator – lubricator)

Check the oil level in the lubricator group (1). If necessary, top it up following
the instructions provided by the FRL group manufacturer.
Check the
lubricator
1
and the oil
level
Discharge condensation from the lubricator filter (1) following the instructions
provided by the FRL group manufacturer.
Check
2
condensation
Chap. 6
- 23/32 -
6.5.3 Cleaning tools and tool holders

Dirt and/or excess oil on the contact surface reduces clamping strength.
• Clean the tool tang (2) and the tapered surface of the tool holder (1).
• Apply a thin layer of lubricant on the tapered seat of the spindle.
• Check the wear of the tool’s cutting edges. Replace the tool if the
cutting edge is damaged or dull.
• Use only tools/tool holders that have been balanced in G1. Rebalance
the tool every time it is sharpened.
1 Clean
NOTA
DANGER!
Risk of flying tool parts.
Safety
warning
Negligence during tool maintenance represents a major cause of accidents.
Clean and sharpen the tools.
Keep tools clean and sharp.
Balance tools in G1 every time they are sharpened.
MAINTENANCE NOTE
Machine Use only one of the greases specified above. Other products may be incompatible with
maintenance the product used by the manufacturer for initial greasing. Incompatible greases mixed
information together or used one after they other may create substances that are damaging for
Chap. 6
- 24/32 -
6.6 Weekly machine maintenance
AUTONOMOUS MAINTENANCE TIMETABLE – WEEKLY CLEANING

QUALIFICATION OF
TYPE OF PERSONNEL
PERSONNEL
1 (one) MACHINE CUT-OFF
Cleaning Operators
ACTIVITY
Safety checks
; , .
After 5 work shifts, specifically clean:
• The filter of the electrical cabinet conditioner. Remove the grid of the
2 Cleaning electrical cabinet conditioner (1).
• Inside the electrical cabinet (2).
• Inside the machine and under the dust guards.
Chap. 6
- 25/32 -
NOTE
DANGER!
Risk of accidents and damage to the machine.
Safety warning
Never use compressed air to clean the machine. The jet of air may push chips and
dust present in the air inside the milling unit or between the contacts of the
electrical components in the electrical cabinet.
Clean the machine and the inside of the electrical cabinet using an industrial
vacuum.
NOTE
DANGER!
Electrocution hazard.
Safety warning
Never use compressed air to clean the machine. The jet of air may push chips and
dust present in the air inside the milling unit or between the contacts of the
electrical components in the electrical cabinet.
Clean the machine and the inside of the electrical cabinet using an industrial
vacuum
Chap. 6
- 26/32 -
6.7 Monthly machine maintenance
AUTONOMOUS MAINTENANCE TIMETABLE – WEEKLY CLEANING

QUALIFICATION OF
TYPE OF PERSONNEL
PERSONNEL
Cleaning Operators
ACTIVITY
Safety checks
; , .
• Discharge the condensation from the electrical cabinet conditioner
2 Clean (1). See the attached manual.
6.7.1 Centralized Lubrication of Linear Axes (OIL LUBRICATION)
MAINTENANCE NOTE
Machine
maintenance
information Check proper functioning of the lubrication system and the oil level in the tank.
Chap. 6
- 27/32 -
6.8 Six-monthly checks and tests
AUTONOMOUS MAINTENANCE TIMETABLE – SIX-MONTHLY CHECKS

QUALIFICATION OF
TYPE OF PERSONNEL
PERSONNEL
Check Operators
ACTIVITY
Safety checks
; , .
• Visually inspect that the electrical cables and cable holding chains are
not damaged and replace damaged components as required.
2 Check • Check that the electrical connectors as fastened tightly.
• Check electrical, electronic and electro-mechanical components and
the electrical cabinet.
Check that all mechanical safety devices are in place and working:
• Enclosure
Check that all pneumatic safety devices are working:

• Low pressure device
Check safety
3 Check that all electro-mechanical safety devices are working:
devices
• Emergency pushbuttons
• Touch-sensitive door edges (where present)
• Supplementary door inter-locking device
• 2-hand control of the portable control panel (where present)
This check is to be considered supplementary for all class I and III safety
devices, which are redundant systems.
Chap. 6
- 28/32 -

Check the • Visually inspect the pneumatic tubes for damage.
4 pneumatic • Check that pneumatic couplings are well fastened.
system
Visually check the mechanical components in continuous movement and
Check the subject to wear for damage:
5 mechanical • Guides, skids and recirculation screws.
components • Components subject to wear: blowers, guards
Chap. 6
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6.9 Extraordinary maintenance
The maintenance described here following requires know-who and specific tools.
This maintenance may be carried out only by the Paolino Bacci S.r.l. Technical Servicing department or
by technical personnel authorized by Paolino Bacci S.r.l.
Pneumatic system:
• Solenoid valve check (heating and binding) and FRL group check, including replacement as required.
Electrical wiring:
• Electrical, electronic and electro-mechanical components
• Check on the electrical manifold of the machining head and brush replacement
• Electrical cabinet conditioner fan
• Overhaul of the electrical cabinet conditioner
Mechanical
• Check that transmission belts are taut.
• Check that mechanical organs are tight (ring nuts, flanges, etc.).
6.10 Decommissioning
Before long idle periods, the machine must undergo the following maintenance:
• Thorough cleaning
• Lubrication of all moving parts
• Surface rust-proofing treatment on all unpainted metal parts (apply oil or MoS2 spray).
• Cover the machine with a water-proof sheet to protect it against dust and humidity.
Chap. 6
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6.11 Dismantling
The machine may have to be moved to different premises during its life cycle. In this case proceed as
follows.
Follow the steps listed below:
STEP OPERATION
1 Shut down the machine and disconnect it from power supply.

2 Remove and put back all tools located in the machine.
3 Clean the machine and protect the corrosion-prone products using special products.
To transport and install the machine in the new premises, use the means and methods
4
described in this manual.
Once the machine has reached the end of its technical life, it must be shut down and must not be used
again for the purposes for which it was originally designed and manufactured; however, you must make
sure the parts and raw materials it is made up can be re-used. Said re-use must not be performed
according to modalities and functions that differ from those for which individual machine parts and the
machine as a whole were designed and manufactured.
PAOLINO BACCI S.r.l. declines any responsibility arising from damage incurred by persons or objects
due to the re-use of individual machine parts for functions or assembly different from the original
functions or assembly. PAOLINO BACCI S.r.l. shall not implicitly or explicitly acknowledge the suitability
of machine parts that were reused after the final de-activation of the machine for dismantling purposes.
Electronic parts
Electronic cards, batteries, storage batteries and buffer batteries of the electrical
switchboard are considered to be hazardous and toxic waste. These parts must be
disposed of by special authorized companies according to directive: 2002/96/EC.
Oil
The oil used during the work cycle of the machine and/or its maintenance must be disposed of according
to the EEC European Directive 75/439 of 16 July 1975.
In accordance to this directive all companies that dispose of used oil are obliged to provide the
competent authorities with information pertaining to the elimination and disposal of used oil and oil
residues.
Please note that according to Presidential Decree (DPR) N° 691 of 23 August 1982, it is obligatory to
address the CONSORTIUM OF USED OIL.
Chap. 6
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Chap. 6
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CHAPTER 7 – Attached documentation and diagrams
7 CHAPTER
Attached documents and
diagrams
Chap. 7
- 1/4 -
TWIN –Use and Maintenance Instruction Manual
INDEX
7 Attached documents and diagrams ...................................................................................... 1
7.1 List of attached documents .....................................................................................................................3
Chap. 7
- 2/4 -
CHAPTER 7 – Attached documentation and diagrams
7.1 List of attached documents
To support and complete the information provided in this manual, PAOLINO BACCI S.r.l. provides a
series of “ANNEXED” documents.
This is a list of the ANNEXES to the manual:
ANNEX A SYSTEM DIAGRAMS
ANNEX B TECHNICAL DIAGRAMS AND GENERAL INFORMATION
ANNEX C SPARE PARTS
ANNEX D OPERATOR INTERFACE SOFTWARE MANUAL
ANNEX E OEM DOCUMENTATION
Chap. 7
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TWIN –Use and Maintenance Instruction Manual
Chap. 7
- 4/4 -

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MACHINING CENTER

Use and maintenance instruction

Document: MAN_ TWIN1213R0en

MACHINE MODELS AND VERSIONS DESCRIBED IN THE MANUAL

Machine description and technical data 3

Controls and use 5

Attached documents and diagrams 7

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1.1 Objective of the manual

1.2 Manual addressees

B - Mechanical maintenance men

C - Electric/electronic maintenance men

D - Mechanical support technicians

E - Electrical/electronic support technicians

F- Lifting and handling equipment operator

1.2.1 Description of symbols, deadlines and abbreviations adopted

1.2.2 Symbols adopted, glossary of terms and illustrations

DANGER, WARNING and INFORMATION notes

Information symbols on the machine

1.3 Glossary of safety terms

In compliance with European Directives 89/391/EEC, 89/654/EEC, 89/655/EEC, 89/656/EEC,

PERSONAL PROTECTIVE EQUIPMENT (PPE)

The following are not pieces of personal protective equipment:

1.4 Use and conservation of documentation

1.5 Update of the manual

1.6 How to request additional copies

1.7 Manufacturer’s Identification and Contact Details

E-mail – general information:

E-mail – spare parts:

1.8 Customer service

Spare parts support:

WEEKDAYS (FROM MONDAY TO FRIDAY)

1.8.1 How to request spare parts

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2.1 Qualification of personnel

2.2 General safety rules

• to conduct a risk evaluation of the machine concerning the characteristics of the

Maintenance personnel is required to:

• Implement a correct machine maintenance timetable.

2.3 Use of Personl protective equipment (PPE)

You are obliged to use protective clothing.

You are obliged to use PVC protective clothing.

You are obliged to use safety boots.

You are obliged to use protective gloves against general mechanical

You are obliged to use protective gloves against chemical risks

You are obliged to use a safety helmet.

You are obliged to use safety goggles with side shields.

You are obliged to use a shield protector.

You are obliged to use a respiratory facial mask (facemask for

You are obliged to use hearing protection devices (earplugs or

You are obliged to use a safety belt for work at height.

2.3.1 Minimum equipment

You are obliged to wear safety clothing.

You are obliged to wear safety shoes.

You are obliged to wear safety gloves against general mechanical

You are obliged to wear hearing protection or earmuffs.

2.4 Safety and warning sings

2.4.1 Description of hazard images

Be careful near protruding or sharp

Watch out for holes in the floor and for any

Be careful near the indicated zones.

Corrosive agents Corrosive agents