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Hermle UWF 902 H, Operating Manual, Page: 20 / 135

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2-1

2. Installing the UWF / 2.1 Safety Precautions Transport

2. Installing the UWF

2.1 Safety Precautions - Transport

Danger

• People must never be allowed to stand under

heavy loads!

When selecting lifting tackle, chains, hawsers,
etc. make absolutely sure that the maximum load
carrying capability is sufficient to lift the transport
weight of the UWF.

Transport weight of the UWF: 5500kg

(weight of the heaviest configuration)

The maximum load carrying capability of lifting
tackle is normally clearly marked.

• Only lift the machine evenly, vertically, and with-

out any jerky movements.

• When transporting the machine by truck, secure

the machine to the loading space and ensure that
slippage cannot occur.

• Only use fork-lift trucks and other lifting trucks with

sufficient lifting power, i.e. capable of supporting
the transport weight of 6000 kg.

• Affix lifting tackle only to the orange-coloured

lifting devices provided, screwed to the side of the
machine.

Summary of Contents for UWF 902 H

Page 1: ...Universal Toolroom Milling and Boring Machine Operating Manual UWF 902 H ...

Page 2: ...1 2 3 4 5 12 13 15 14 9 10 11 8 7 16 6 17 ...

Page 3: ...Quill clamping 5 Spindle slide 6 Operator console 7 Spindle start key 8 Swivelling arm 9 Cooling lubricant level indicator 10 Cooling lubricant tank 11 Machine table 12 Protective bellows 13 Tool changer sliding door 14 Compound slide rest 15 Machine light 16 Pull out writing desk 17 Main switch ...

Page 4: ...Control TNC 426 ...

Page 5: ... comprehensively familiarized with the new HERMLE Universal Toolroom Milling and Boring Machine Please pay particular attention to the safety instructions marked by the danger symbol We wish you every success with the HERMLE UWF Universal Toolroom MIlling and Boring Machine Yours Sincerely Maschinenfabrik Berthold Hermle AG B 129 H426 10 0196 E The machine in this operating manual conforms to the ...

Page 6: ...udence called for Mistakes could lead to injury of the machine operator or third parties Note Ignoring this remark can lead to damage of the machine the tool or the workpiece Publisher s Note Published by Maschinenfabrik Berthold Hermle AG Post Box 1240 D 78556 Gosheim Federal Republic Of Germany This document may not be altered reproduced or given to third parties nor used in contravention of our...

Page 7: ...7426 95 Extension Technical problems Hotline After Sales Service Tel 3723 Fax 3709 Programming Problems Tel 6185 Tel 6187 Spare Parts Tel 6221 Tel 6222 Tel 6223 Head of Service and Assembly Mr Betting Head of After Sales Service Mr Koch Hotline Service Mr Seemann ...

Page 8: ... Technical Details 1 4 1 5 Machine Dimensions Space Needed 1 6 1 6 Base Plan 1 7 2 Installation 2 1 Safety Precautions Transport 2 1 2 2 Transport Instructions 2 2 2 3 Installation Instructions 2 5 2 4 Cleaning 2 7 2 5 Removal of the Transport Safeguards 2 8 2 6 Electrical Connection 2 9 2 8 Preparation for Initial Start Up 2 10 2 9 Initial Start Up 2 13 ...

Page 9: ... 3 12 3 3 9 Compensation of the Thermal Expasion of the Y Axis 3 13 3 4 Tool Clamping 3 14 3 5 Data Transfer 3 15 3 6 Cooling System of the Electrical Cabinet 3 15 3 7 Horizontal Milling 3 16 3 8 Vertical Milling 3 17 3 9 Swivelling of the Vertical Head 3 18 3 10 Adjusting the Vertical Head 3 18 3 11 Extending the Quill 3 20 3 12 Cooling System 3 21 3 13 Moving Free 3 22 3 14 Spindle Orientation 3...

Page 10: ...lamping table UWF 902 S 4 16 Universal clamping table UWF 1002 S UWF 1202 S 4 17 Universal clamping table UWF 902 H 4 18 Universal clamping table UWF 1002 H UWF 1202 H 4 19 NC rotary table UWF 900 4 20 NC rotary table UWF 902 S 4 21 NC rotary table UWF 1002 S UWF 1202 S 4 22 NC rotary table UWF 902 H 4 23 NC rotary table UWF 1002 H UWF 1202 H 4 24 NC controlled swivelling rotary table UWF 1002 H U...

Page 11: ...8 5 11 Bevel Gear Lubrication Vertical Milling Head 5 19 5 12 Maintenance of the Hydraulic Power Pack 5 20 5 13 Maintenance of the Central Lubrication System 5 22 5 14 Maintenance of the Circulatory Lubrication System 5 22 5 15 Rigid Clamping Table Maintenance 5 24 5 16 NC Swivelling Rotary Table Maintenance 5 24 5 17 Internal Coolant Supply through Spindle 5 24 5 18 Removal Feed Motor Z Axis 5 25...

Page 12: ...ght Angle Hole Grid 8 4 8 3 Reaming 8 6 8 4 Hollowing 8 8 8 5 Peck Drilling 8 10 8 6 Pocket Milling 8 14 8 7 Groove 8 18 8 8 Slot 8 20 8 9 Circular Groove 8 22 9 Appendix List of equipment for the chain magazine and UTC 34 10 Control HEIDENHAIN Programm Instructions ...

Page 13: ...nformation 1 1 Description of the Machine The Hermle UWF 902 H is an efficient numerically controlled milling machine tool designed for machining both the largest and the smallest work pieces Equipped with a rigid clamping table the machine can deal with workpieces of a maximum weight up to 450 kg and a maximum mounting area of 900 x 528 mm The most complicated workpieces weighing up to 300 kg can...

Page 14: ...1 2 150 150 900 130 500 458 16 10 195 65 450 600 1 2 Speed Torque Power Curves 1 2 Speed Torque Power Curves ...

Page 15: ...anger arm clears the outer edges of the workpiece and or the workpiece holding device The need for free movement of the changer arm should be taken into consideration when programming Where there is danger of collision rearrange workpiece Note If you incline the vertical milling head from its zero position into an angular position in order to produce inclined surfaces or borings the working range ...

Page 16: ...55 mm Quill stroke vertical 75 mm Feed Drive Feed motor for each axis AC brushless Feed range in X Y and Z axes manual programmable 1 2000 10000 mm min Feed force in all axes at 80 load factor 6 000 N Rapid traverse in all axes 10 m min Noise Level Machine noise place of emmission value according to German machine noise regulation 3 GSGV paragraph 1 section c and d 78 dB A Working Range Longitudin...

Page 17: ... votage 400 V 3 phase 50 Hz Control voltage 220 V AC 24 V DC Total connection valve 16 KW Total connection valve with IKZ 19 KW Dimensions Weight HERMLE UWF 902 H including all round protective cabin length x width x height 2 95 x 2 20 x 2 30 m Space Required length x width 4 55 x 3 60 m Total weight including rigid table all round protective cabin tool changer and swarf conveyour ca 6000 kg Tool ...

Page 18: ...1 6 1 5 Machine Dimensions Space Needed 1 5 Machine Dimensions Space Needed for UWF 902 H with UTC 34 ...

Page 19: ...ad related to the complete installation surface of the machine approx 1235 kg m2 Max load on the front points of support F1 or F2 when the angle table is positioned eccentrically approx 2080 kg Max foundation pressure of F1 or F2 approx 11 0 kg cm2 Complete installation surface of the machine Supporting surface of the machine Electric Pneumatic Cabin support ...

Page 20: ...UWF 5500kg weight of the heaviest configuration The maximum load carrying capability of lifting tackle is normally clearly marked Only lift the machine evenly vertically and with out any jerky movements When transporting the machine by truck secure the machine to the loading space and ensure that slippage cannot occur Only use fork lift trucks and other lifting trucks with sufficient lifting power...

Page 21: ...2 2 2 2 Transport Instructions Drawn without cabin Transport with cabin 4 7 6 1 2 3 5 150 440 1 3 2 4 5 6 Machine with tool changer UTC 34 ...

Page 22: ... with a fork lift truck or crane and pull the pallet away from underneath For safety let the machine down a little and transport it carefully to the place where it is to be erected Transporting the Machine with a Fork lift Truck When using a fork lift truck ensure that it is capable of lifting at least 6000 kg The fork lift must be equipped with a boom at which a cross beam can be attached 6 Rope ...

Page 23: ... rope could damage the paintwork if directly connected to the machine In addition uncontrolledrotationofthemachinearound the transport rope is prevented Note When transporting the machine the HERMLE lifting device should normaly be used Under no circumstances should ropes or lifting tackle be attached to the following equipment Machine table Compound slide Spindle slide Lifting capacity min 6000 K...

Page 24: ...e Remove the Lifting Devices Once the machine has been erected at the chosen location remove the orange coloured lifting device parts These parts should be kept with the machine should the machine be moved again on a future occasion Levelling Pads Four levelling pads 1 can be ordered as an option These have an adjustment range of 63 73 mm Push the levelling packs at the lowest setting under the ma...

Page 25: ...bolts If the floor is suitable the fixing blocks can also be fastened by means of heavy duty plugs or anchor bolts e g Fischer No 51351 The schematic illustration above shows a cross section of a fixing block anchored to the floor with stone bolts The distance from the upper edge of the machine foot to the machine park floor must be at least 183 mm so that the cooling lubricant tank can later be p...

Page 26: ...ces in particular the guideways have been sprayed with a corrosion prevention material Use a soft cloth and benzine to remove this from uncovered surfaces After carefully cleaning the Y axis guideway a lubricating oil must be applied use Type DIN 51517T1 C68 or DIN 8659 T2 CG 68 see lubrication table Inordertocleanthepaintedsurfaceswerecommend the use of a standard household cleaning solution Do n...

Page 27: ... only when the machine is at its final site Turn out the hexagon socket screws M8 1 at the jib of the spindle slide and the two hexagon socket screws M12 2 on the left and right below the jib of the cross slide rest in the machine column see the following pages If the machine will be moved later attach these safeguards again to avoid that the machine will be damaged Move cross slide rest free as d...

Page 28: ...t s left hand door The choice of cable cross section to be used for connection to the mains should be made according to the connection conditions laid out in the circuit diagram The mains connection within the electrical cabinet should be made as shown on the illustration In the process the cable bushing should be sealed using a rubber grommet Connect the cable to the terminals L1 L2 L3 N and PE P...

Page 29: ... may occur The limit values of these harmonic oscillations are specified in VDE 0160 part 5 3 1 2 If these requirements are not met please contact the responsible electric power station before connecting the machine As remedial measure a filter can be added to the unit If necessary please contact us When the machine is connected to a mains with an earth leakage circuit breaker an isolating transfo...

Page 30: ...2 11 2 2 7 Preparation for Initial Start Up 4 1 ...

Page 31: ...ication oil level lies between the two markings 3 With the cooling lubricant tank inserted see notes in chapter 5 fill up cooling lubricant via the protective enclosure s return sieve 4 Fill the lubricating oil circulatory system with the oil provided until the oil level can be seen in the inspection windows Note Before initial start up of the 4th and 5th axis please see chapter 4 2 8 Preparation ...

Page 32: ...ol unit are rendered inoperative Press key CE 2 In case the EMERGANCY STOP chain is not interrupted key 3 will light up The dialog window will show the message TRAVERSE REFERENCE POINTS Note In case an emergency switch is pushed or the emergency chain is interrupted the following message will appear RELAY EXT DC VOLTAGE MISSING key 3 will not be lit Release emergency stop or check the cause Switch...

Page 33: ...ction i e upwards To do so press the direction key Z 8 Please check that the feed override 9 is not set to minimum as in this case the drive motor will not start The table will drive upwards The display Z axis will disappear Remove the transport safeguard of the cross slide rest Press the direction keys X and Y the messages X axis and Y axis will disappear Note The feed must be at least 20 mm The ...

Page 34: ... must always be relieved of pressure via the hand wheel or the emergency valves Switching off of the hydraulic system is not adequate Safety features may never be manipulated switched off or in any other way by passed Before performing work on the feed motor and the toothed belt Z axis absolutely read the chapter Disassembly of the feed motor Undernocircumstancemaythemachinebecleaned withcompresse...

Page 35: ...anual operation the rapid feeds are restricted to 2 m min Aftertheendofaprogramthecabincanbeopened 3 1 Safety Instructions Machine Safety Machine Safety To ensure maximum universatility HERMLE uni versal milling and boring machines can be driven either automatically or manually Therefore the safety regulations for machine tools and production systems TC 143 apply Consequently there are different s...

Page 36: ... while pushing the acceptance key 5 max speed 800 1 min Note Setupandmaintenanceworkmustonlybeperformed by specially trained personnel Operating Mode III Universal Hand Operation This mode is necessary for example to work with the quill After the end of a program the doors can be unlocked by pressing keys respectively Withdoors opentheaxisdrivesremainconnected anddrivingtheaxeswithreducedspeedispo...

Page 37: ...d tool Particular care needs to be taken with large boring heads or similar tools Make sure that the tools in use are suitable for the selected speeds and machining tasks The use of grinding wheels is not allowed The quill may only be used to drill counterbore and bore Using the quill as an extension for the tool for milling operations is only allowed when the cabin is closed Duringworkingwiththeq...

Page 38: ...operation 2 Lateral enclosure door will is not locked electrically but monitored It can be locked mechanically and will then be monitored electrically 3 Tool magazine door at the back side UTC 34 opening this door will stop the magazine 3 2 Starting the Machine General 3 2 Starting the Machine General 1 2 3 ...

Page 39: ...ne General Turn the main switch 1 on the electrical cabinet to the ON I position The machine will now automatically carry out an internal memory check All control keys are rendered inoperative for the duration of the check around 2 minutes Press the CE key 2 In case the EMERGENCY STOP loop is not interrupted key 3 will be lit In the dialog field the following will appear PASS OVER REFERENCE POINTS...

Page 40: ...ation Should it not be possible to approach the reference points in this way or should it be necessary to move the axes immediately in the X plus Y minus or in the Z minus direction then please proceed as described on page 2 16 of the chapter on Initial Start Up This is the case if for example the machine is equipped with an NC swivelling rotary table which is sitting in the uppermost position and...

Page 41: ...on is kept pressed By means of the self hold function By activating a direction key and the NC Start button 3 the corresponding axis will continue to move in the direction selected even after leaving hold of the key until it is stopped by activation of the NC Stop button 4 In both types of operation the axes can be moved at 50 of their maximum speed by additionally pressing one of the rapid traver...

Page 42: ...led in three different ways Continuously via the two plus minus keys on the manualoperationconsole Priortothis thedesired axismustbeselectedwithoneoftheaxis selection keys The letter designating the activated axis appears on the screen in a complementary colour Directly using the electronic handwheel 12 The subdivision factor can be entered as a whole number at any time in the handwheel mode of op...

Page 43: ...n Full Sequence Select this mode of operation with key 15 in order to work continuosly through an already created pro gram In this mode of operation the tool data TOOL DEF in the tool storage T1 T254 can be changed You can find further more detailed information in the instructions handbook for the control system 3 3 5 Program Run Single Block Select this mode of operation with key 14 in order to w...

Page 44: ...res of circles Further moredetailedinformationcanbefoundinthe instructions handbook for the control system 3 3 7 Test Run Select this mode of operation with key 17 in order to test a program With the test run the work cycle can be simulated on the screen without the machine operating The processing of the workpiece is graphically displayedonthescreenandsocaneasilybemonitored Mounting elements are ...

Page 45: ...ically after the blockadvancemodebypressingsoftkeyRESTORE POSITION 3 3 Operating Modes 3 3 8 Block Advance M Functions during Block Advance Mode During the use of the block advance mode there are tow different kinds of M functions which need to be distinguished 1 M Functions which are not memorized during Block Advance M00 Program stop M06 Tool changing call manual M15 Division impuls M18 Lubricat...

Page 46: ...e feeler will be displayed after pressing NC START Display of any of these messages indicates a defect in the machine Temperature vertical head Temperature spindle slide Temperature column If one of the above messages is displayed the machine remains ready for operation Additional M Functions M77 Display of the Temperatures of the Temperature Feelers Via M function M77 the actual temperatures of t...

Page 47: ...stem will release the tool and eject it Insert new tool Please make sure that the groove in the flange matches up with the drive keys Pressthetoolchangingbuttononce Thetoolispulled into the spindle 3 4 Tool Clamping Standard equipment of the Hermle UWF is a tool clamping system according to DIN 69871 and tool draw bolts to DIN 69872 19 form A ISO 7388 2A The clamping system features a cone accordi...

Page 48: ...er Aheatexchangerfortheelectricalcabinetisstandard equipment The heat exchanger uses the cooler outer air to cool theheatedaircirculatingintheinterioroftheelectrical cabinet As the two air circulations are kept separa te from each other no impurities can enter the electrical cabinet Very fine dust particles which can be produced by grinding or eroding machines can cause faulty operation in the ele...

Page 49: ...een will show the message swing off vertical head Loosen the six screws of the milling head key 19 Pull the vertical head with both hands towards you until it reaches the stop and swing slowly to the topside by 90 Turn the releasing lever 3 to the left and at the same time push the vertical head carefully back ward until it engages The screen shows the message PROTECTIVE COVER Attach the large pro...

Page 50: ...owly swivel the milling head by 90 to the downside until the fastening surfaces are parallel Turn the release lever to the left push the vertical millingheadstronglyagainstthefrontofthespindle slide and tighten the four fastening screws 2 The message Swivel out the V head disappears Themachineisswitchedovertotheverticalspindle by pulling the V head out of its parking position Attachthesmallprotect...

Page 51: ...osition have changed repeat the sequence If the vertical head is swivelled tools can only be inserted manually 3 10 Adjusting the Vertical Head To bring the milling head back to vertical position or to adjust it follow this sequence Check whether the fixing pin 1 is pulled all the way out to the rear stop Loosen the 4 screws 2 key 19 at the flange of the vertical head Swivel the head clockwise app...

Page 52: ...r works be off it needs to be corrected The fixing pin is mounted excentrically and can thus be adjusted Loosen the 8 screws 2 key 19 at the flange of the vertical milling head Loosen the fixing screw 3 allen key 3 of the fixing pin Turn the excentric bearing of the fixing pin at the hexagon 4 key 27 until the position of the milling head is correct The fixing screw 3 needs to be tightend very sen...

Page 53: ...s handle 2 The maximum quill stroke is 75 mm To clamp the quill in the desired position turn the clamping lever clockwise upwards The scale ring can be turned To do so loosen the screw 5 at the cross handle With extended quill tool changing can only be effected by hand Danger For the automatic tool changing make sure that the quill is retracted and the clamping lever 1 points upwards Danger of col...

Page 54: ... see also M funstions page 3 28 If desired the coolant can be switched on manually by using key 8 on the keyboard see picture page 3 4 Theboardforthecoolantequipmentislocatedonthe right hand side of the machine Via the two valves all coolant tubes can be fed individually The regulator cock 1 controls the coolant supply at the vertical head Acoolantnozzlewithhoseisoptionalavailableforthe UWF It can...

Page 55: ...aniously pushing the acceptance key 2 and key S3 1 which is located in the electrical cabinet A second person needs to push key S3 during the following sequence Push the acceptance key Erase the message on the screen by pushing Reset 3 3 13 Moving Free Select the appropriate axis by using the direction keys 4 The axis can now be moved free and key S3 can now be released After switching on the main...

Page 56: ...l position at 0 degree The drive keys of the spindle are parallel in respect to the grooves of the rigid table Application of the cycle Spindle orientation and how to change the angular position can be read up in the manual for the control unit 3 15 Closed Loop Oil Lubrication The closed loop oil lubrication provides lubrication oil to the spindle slide the gear box and the milling head whilst par...

Page 57: ...lubrication impulses are monitored by the control unit depending on the time and the travels of the machine After a defined travel or latest after 1 hour an impulse is released automatically The oil level and the correct pressure of the central lubrication system are permanently monitored A disturbance of the lubrication system is immediately indicated on the screen in order to avoid damage of the...

Page 58: ...t contours clockwise for islands 1 channel milling clockwise pocket contours anti clockwise for islands Bit 1 Sequence for clearing and channel milling 0 First mill the channel then clear the pocket 2 First clear the pocket then mill the channel Bit 2 Joining of programmed contours 0 Contours are only joined when the milling centre tracks cross 4 Contours are only joined when the programmed contou...

Page 59: ...100 mm 7330 11 950 01 Tool change position M92 Y axis 200 mm 7330 12 950 02 Tool change position M92 Z axis 300 mm 7330 13 7410 Measurement factor cycle affects 2 or 3 axes 0 0 3 axes 1 on the processing level 7330 14 7260 Central tool storage 0 0 no central tool storage 1 254 central tool storage input number of tooles 7330 15 7295 Set reference point blocked 0 Bit 0 0 X axis not blocked 1 X axis...

Page 60: ...articular version of the machine is entered the factory It is to be found in the user parameters Ifyouwishtochangethemachine soptionalfeatures theseparametersmustbere enteredcorresponding to the changed options This is necessary in order to adjust the control to the modified for equipment In order to determine the machine code add the position value of the current options and enter this value in t...

Page 61: ...Set Mark Pos Evalution Value Column Wireless touch probe TS 550 Option 2194 4 Axis keys effective during Standard 2195 8 manual mode Result no incrementalmeasurement Swarf conveyor Option 2196 16 NC precision dividing head Option 2197 32 HTH 125 160 NC rotary table Option 2198 64 No 116 25 Heidenhaindigitizing Option 2200 256 Monitoring of the V head position off 2201 512 All round protection Stan...

Page 62: ...ientation M 20 Swarf conveyor on cyclic Only with locked cabin M 21 Swarf conveyor off M 22 FREE M 23 Tilting NC rotary table release universal table release M 24 Tilting NC rotary table clamp universal table clamp M 25 Table plate release M 26 Table plate clamp M 29 Swivel in out vertical head M 30 Program end with jump to start of programm M 31 Open cabine at M02 M30 Automatic unlocking of the c...

Page 63: ... The chain magazine holds a total of 34 tools The tool changer can change tools with up to 8 kg in weight a lenght of maximum 250 mm and a diameter of 90 mm 4 1 2 Technical Data Tool Changer Number of tools 34 Tool coding fixed according to place Tool diameter regular max 90 mm with free adjacent tool places max 125 mm Tool lenght from spindle nose Magazine max 250 mm Tool weight max 8 kg Magazine...

Page 64: ...4 2 4 1 2 Technical Data Tool Changer Tool changing horizontal Tool changing vertical ...

Page 65: ...Technical Data Chain Magazine 1 Operating station of magazine 2 AC motor 3 Gear 4 Tool holder 5 Chain 1 2 3 4 5 Loading and unloading station of the tools via tool changer Station for manual loading and unloading ...

Page 66: ...rve as an optical check for the adjacent tools Note Tools with diameters larger than 90 mm must only be changed when there is no tool in the spindle or in case this tool has been previously taken out via code T0 Danger of collision Also tools which are loaded may never extend into the red sectors The magazine places are fix coded This means that the control recognizes the respective place but not ...

Page 67: ...he magazine cannot be advanced Automatic movement is only possible with closed magazine door Inserting a Tool Position the magazine via keys 1 and 3 at the correct pocket Press key 2 the tool pocket 4 will open Insert the tool and hold it in place Press key 2 again the tool pocket 4 will close Danger Don t hold the tool above the flange Otherwise there will be a danger of pinching when the tool po...

Page 68: ... Stellung steht Danger of collision Program run Modes Program run single block Program runautomatic Positioning manual data input 1 2 3 4 5 The vertical tool change is initiated via command TOOL CALL To achieve optimum tool changing times the tools can be prepared via command TOOL DEF Programming Example TOOL CALL 22 TOOL DEF 4 Tool will be prepared LX 100 Y 100 Z 100 Fmax M03 IZ Z 300 TOOL CALL 4...

Page 69: ...ine Flag list Flagareasaredeterminedinthecontrolbywhichthe user has the possibility to inform itself about the current magazine position and about a tool which possiblyisinthespindle Thisinformationiskeptafter switchingoffthemachineandcanbeselectedviathe MOD function key number 807667 list flag The information is binary coded Flag area M 1000 M 1007 contains the current position of the magazine Fl...

Page 70: ...ng a TOOL Call a TOOL DEF or while a tool has been deposited this can be removed by 40 or 41 Select Functions After the table is shown on the screen the functions can be selected by pressing the up down arrow Activate Functions The functions 40 41 42 can only be activated with closed cabin Example Function 40 has been activated Pressing key NC START will start the sequence During this the colour o...

Page 71: ...ve Open spindle valve Passing over the reference points with unfavourable tool changer position after switching the main switch on Select file KundHelp TNC message disappears Drive gripper unit back Drive tool changer Close cabin 10 down 8 Leave Help file Leave file KundHelp Pass over reference Pass over reference Pass over reference points X Y Z points X Y Z points X Y Z Close spindle valve Close...

Page 72: ...ece fixtures and clamping devices are level Possible indentations or burrs must be smoothed out using a file or an oilstone in order to avoid damaging the high quality table surface Clamp the workpiece as centrally as possible and avoid an asymmetrical weight distribution Only use T groove tongues that fit in order to avoid damage to the table s T grooves If the rigid clamping table is not require...

Page 73: ...4 H7 63 47 900 465 4 2 2 4 2 2 Technical Details Clamping area 900 x 458 mm Table weight 275 kg Maximum load carrying capability of table 500 kg Number of T grooves 7 T groove spacing 63 mm T groove width 14 H 7 ...

Page 74: ...4 12 0 450 180 18 468 30 85 10 465 47 63 14 H7 ca 245 ca 470 ca 75 208 0 500 73 92 4 2 2 ...

Page 75: ...nd spray them with a rust prevention agent With the direction keys of the control the cross slide rest can be precisely positioned against the rigid clamping table Put the contact surface of the rigid table against the key ways of the cross slide rest and fasten with the8holdingbolts 1 M16 Therigidtablecanbe movedintoanexacthorizontalpositionwiththeset screws 2 M16 and fixed by the two nuts 3 Remo...

Page 76: ...y The tilting range for the laterally flattened clamping plate is 15 from the machine and 45 towards the machine and 15 and 30 for the round clamping plate Draw chucks in different sizes or a vertical arbor holdercanbeorderedatoursparepartsdepartment You will find the telephone numbers in the pocket of the cover Before clamping carefully clean the table and the clamping grooves Check the flatness ...

Page 77: ...rsal clamping table with dividing arbor No 103 14V03 Direct dividing unit with detent positions 48 Indirectdividingunitbywormgeardrivewhichcanbe swung out total transmission ratio 1 90 Universal clamping table with encoder No 103 31V12 With worm gear Total transmission ratio 1 90 Handwheel with encoder directly attached to the dividing arbor Indication step 0 001 Round clamping table No 103 14V09 ...

Page 78: ...4 16 4 3 2 Technical Data 0 450 180 258 18 468 85 30 220 175 ca 75 Ø 650 63 Ø 420 32H7 208 70 92 102 587 10 495 116 688 456 ...

Page 79: ...y clean the contact faces to remove dirt and swarfs and spray them with a rust prevention agent With the direction keys of the control the cross slide rest can be precisely positioned against the universal clamping table Put the contact surface of the universal clamping table against the key ways of the cross slide rest and fasten with the 6 screws 4 M 16 The universal clamping table can be moved ...

Page 80: ...the two eye bolts with inserted tongues at the ends of the centre T groove and lift the table plate with a suitable lifting tackle Treat all exposed areas of the table plate with a rust preventionagent Attaching the Table Plate Thoroughly clean the supporting surfaces to remove dirt and swarfs Place the table plate carefully on the universal clamping table base The table plate is exactly fixed by ...

Page 81: ...d instead of the hand crank divisions of 2 5670 can be adjusted With the optional encoder each angular position desired can be controlled via the control Swivelling the Table Loosen the 6 holding bolts M12 5 Insertthehandcrank 6 intotheswivellingmodule 7 Turn the universal clamping table into the desired angular position 30 by means of the hand crank Retighten the 6 holding bolts To get the zero p...

Page 82: ...shafts can be clamped with the hand crank 6 viathefixingdevice 10 fortheSK40holder tips for arbor holder draw chuck clamping piers mandrels etc Attachment of the vertical arbor holder Remove the table plate TightenthearborholderwithtwoholdingboltsM12 tothesupportplateoftheuniversalclampingtable The functions of the table will be completely kept 4 3 5 Operation Universal Clamping Table ...

Page 83: ...le with the 500 mm diameter clamping plate The 650 mm diameter clamping plate can only be tilted up to a maximum of 4 Draw chucks in varrious sizes can be ordered at our Spare Parts Department The phone number can be found in the pocket of the cover Before clamping the surface of the plate and the clamping grooves should be carefully cleaned 4 4 NC Rotary Table Check that the workpiece fixtures an...

Page 84: ...4 22 3 2 1 4 4 NC Rotary Table 1 500 mm diameter clamping plate 2 650 mm diameter clamping plate ...

Page 85: ...e A C servomotor 8 Nm Max rotational speed 11 r p m Machining moment 1000 Nm Definition of rotary encoder 0 001 Total dividing error 0 002 All details refer to the base of the NC rotary table Table Plates 500 mm diameter clamping plate delivered as standard feature Clamping area 500 mm Ø T grooves Number spacing width 7 63 14 H7 Tilting range Right left 30 Rotating range 360 Weight 65 kg 650 mm di...

Page 86: ...4 24 0 450 180 18 468 92 A 208 ca 75 85 265 463 415 Ø 500 63 Ø 32H6 10 491 Table plate Dimension A min Dimension A max Ø 500 mm 102 mm 583 mm Ø 650 mm 102 mm 578 mm 4 4 2 Technical Data ...

Page 87: ...al allen wrench 14 mm is part of the standard equipment Switch the main switch of the machine to 0 1 Remove the covering sheet metal at the top left hand side of the cabin by losening of the six screws Insert the protective tube into the respective opening Plug the two hydraulic hoses into the connectors 8 and 9 Connect the central lubrication hose to the plug 10 Remove the bridging plug from the ...

Page 88: ...fter removal of the table cover all finish machined surfaces of the table with a rust prevention agent If after removal of the NC tabel a rigid table is attached you must first cancel the fourth axis to enable the control to recognize the modified configuration To achieve this switch over to programming mode by pressing key 4 press key Mod 5 and 4 4 3 dial in key number 95148 You are now in the ta...

Page 89: ...n each side and remove the brass clamps 4 from the holder 5 With a pulling off device pull the two cylindrical pins 6 vertically upwards out of the table plate Loosen the 8 holding bolts 7 M 12 in the upper surface of the table plate and remove them Tighten the two eye bolts with inserted tongues at the ends of the center T groove and lift the table plate with suitable lifting tackle Note When put...

Page 90: ...ct position Tighten the bolts of the clips 3 With command M 25 release the clamping and check the gap between the clips and the table plate s contact areas with a feeler gauge The gap should be between 0 1 and 0 2 mm Fasten the two side covering plates 2 over the clamping device and mount the main front cover plate 1 on the table again Note For the table plate with diameter 500 mm use the two clos...

Page 91: ...4 29 4 4 5 1 Cover plate 2 Recess 3 Taper pin 4 Hand crank ...

Page 92: ...the desired angular position Note the limited tilting range when using larger table plates Clamp the table again by entering command M 24 Turning the Table Plate In manual mode the NC rotary table is clamped However by activating one of the direction keys the clamping is released and it can be turned via the direction keys or the electronic handwheel In the program run the NC rotary table s clampi...

Page 93: ...ls can register the most diverse workpiece positions The following configuration is offered Probe system cordless infrared 3 D probe The cordless infrared 3 D probe can be kept in the tool magazine and automatically changed The magazine pocket 34 is reserved for the 3 D probe it must be deposited in this pocket This ensures that the milling spindle cannot be switched on after insertion of the 3 D ...

Page 94: ...fore pay heed to optimum swarf formation during operation and in general avoid producing stringy or spiral swarf Enter the command M 20 to switch on off the swarf conveyor periodically Deactivate the cycle with the command M 21 The swarf conveyor stops when the cabin will be opened Ifnecessary theswarfconveyorcanalsobeswitched on and off with keys 1 and 2 at the operator controls Iftheswarfconveyo...

Page 95: ... complex work operations as the production of barrel cams helixes helical gearing etc Carefully clean the table surface and the clamping grooves before clamping If the NC Precision deviding head is not required for an extended period e g weekend holidays etc clean the table thoroughly to remove dirt and swarf and wipe the clamping surface vigorously with a clean oil soaked cloth ...

Page 96: ...ding arbor 100 Nm 200 Nm Stop moment of the hydraulic arbor clamping 250 Nm 625 Nm Static axial load central 15 kN 30 kN Max tilting moment of the workpiece 300 Nm 7200 Nm Standardequipment Locking air connection with service unit Equipment Face plate Ø 1500 mm Ø 200 mm Tailstock fixed quill stroke 40 mm 40 mm Holding flange for concentric chuck Ø 100 160 mm Ø 160 200 mm Concentric chuck DIN 6350 ...

Page 97: ...in switch of the machine to 0 1 Remove the covering sheet metal at the top left hand side of the cabin by loosening the six screws Insert the protective tube 8 into the respective opening Plug the hydraulic hose into the connector 9 Plug the pneumatic hose into the connector 14 Remove the bridging plug from the socket 11 Connect the 12 pole connection cable to the respective socket 11 and secure i...

Page 98: ...iding head treat all exposed areas with a rust prevention agent If you remove the NC dividing head you must first cancel the fourth axis to enable the control to recognize the modified configuration To achieve this select the programming mode by pressing key 4 then press key Mod 5 and dial in the key number 95148 Youarenowinthetableofthemachineparameters Change the parameter MP50 MP10 to 7 Confirm...

Page 99: ...4 37 4 8 NC Precision Dividing Head 4 8 4 Clamping Measurements NC Precision Dividing Head RW NC 125 Tailstock accessory Dividing head with vertical dividing axis Face plate accessory Stroke quill 40 ...

Page 100: ...4 38 4 8 4 Clamping Measurements NC Precision Dividing Head RW NC 160 Stroke quill 40 Tailstock accessory Dividing head with vertical dividing axis Face plate accessory ...

Page 101: ...ayhappenthatthe tank of the gravity filter band unit overflows Float switch The float switch is located on the support plate near bythecoolantlubricantpumpandcontrolsthispump It prevents an overflow and switches on the pump whenthecoolanttankisapprox 2 3filled Thepump forwards the coolant lubricant into the gravity filter band unit until the float switch switches off Adjust the Float Switch Adjust...

Page 102: ... change any components that work faultlessly Never change a setting and do not extend rearrange or reconstruct any machine parts Comply with the specified maintenance intervals according either to actual machine use or to set time periods See following pages Distinguish between repair and maintenance Our service department is at your service in case of technical faults Possible causes of faults an...

Page 103: ...sieve 2 Cooling Lubricant tank 3 Bevel gear lubrication vertical milling head 4 Hydraulic unit 5 Oil circulatory lubrication system 6 Tool clamping system 7 Guideway stripper Y axis 8 Main spindle 9 Protective spiral Z axis 10 NC rotary table not shown 12 Vertical milling head ...

Page 104: ...lling head monitor oil level 5 19 4 hydraulic unit monitor hydraulic fluid level 5 20 5 oil circulatory lubrication system monitor oil level 5 22 6 tool clamping system clean spindle taper 5 14 10 NC rotary table monitor oil level 5 12 Weekly or after every 40 Operating Hours No Maintenance Item Details Page 2 cooling lubricant unit check cooling lubricant 5 16 7 guideway stripper Y axis check rep...

Page 105: ...nance Item Details Page 4 hydraulic unit change oil filter 5 20 8 check the pull in power of the main spindle if necessary have this 5 14 performed by HERMLE service staff 14 swivel in and out the vertical milling head several times if it will be swivelled up and down seldom or never 13 tool holder at magazine check holding force and positioning or have this performed by HERMLE service staff 14 Re...

Page 106: ...ance Item Details Page 10 NC rotary table oil change 5 12 10 NC rotary table check toothed belt replace if necessary 5 13 3 bevel gear lubrication vertical milling head oil change 5 19 4 hydraulic unit change hydraulic fluid 5 20 5 oil circulatory lubrication system oil change 5 22 ...

Page 107: ...Point Lubricant Details Page 1 central lubrication system CG 68 5 8 5 21 2 circulatory lubrication system CLP 68 5 7 5 22 3 vertical milling head CLP 150 5 9 5 19 4 hydraulic power pack HLP 46 5 11 5 20 5 NC rotary table not shown PGL 220 5 10 5 12 6 Maintenanceunit HLP 46 ...

Page 108: ...rlubricantsupplieraboutwaste oil disposal opportunities 5 4 1 Circulatory Lubrication System We recommend the use of lubricating oil DIN 51517 T3 CLP 68 Brand Type of Oil Initial Filling ARAL Aral Degol BG 68 ADDINOL Addinol CLP 68 BP BP Energol GR XP 68 CASTROL Alpha SP 68 ELF Reduct ELF SP 68 ESSO Spartan EP 68 HOUGHTON Hydrolubric VG 68 MOBIL Mobilgear 626 X OEST Oest Gearol C LP 68 SHELL Shell...

Page 109: ...bric VC 68 MOBIL Mobil Vactra Oil No 2 X OEST Oest Gleitöl CG 68 SHELL Shell Tonna Öl TX 68 TEXACO Way Lubricant 68 Alcor Oil 68 Hydr TOTAL Total Drosera MS 68 TRIBOL Tribol 1060 68 ZELLER GMELIN ZET GE T6 EP ISO 68 FUCHS RENOLIN DTA 68 KLÜBER LAMORA D 68 X initial filling n a type of oil not available from this supplier at time of writing The lubricants used for the initial lubrication have been ...

Page 110: ...lgear 629 X OEST Oest Gearol C LP 150 SHELL Shell Omala Öl 150 TEXACO Meropa 150 Alcor Oil DD 150 TOTAL Total Carter EP 150 TRIBOL Tribol 1100 150 ZELLER GMELIN ZET GE ICL 150 ISO FUCHS RENOLIN CLP 150 PLUS KLÜBER X initial filling n a type of oil not available from this supplier at time of writing The lubricants used for the initial lubrication have been tested on our machines We can only guarant...

Page 111: ... 5 4 4 NC Rotary Table We recommend the use of lubricating oil 220 or PG 220 Brand Type of Oil Initial Filling ARAL Aral Degol GS 220 ADDINOL Addinol PGL 220 Addinol PG 220 BP BP SGR XP 220 CASTROL ELF ESSO HOUGHTON MOBIL Glygoyle 30 X OEST SHELL Tivela Oel WB TEXACO TOTAL TRIBOL Tribol 800 220 ZELLER GMELIN FUCHS KLÜBER Klübersynth GH 6 220 X initial filling n a type of oil not available from thi...

Page 112: ...46 Aral Vitam DE 46 ADDINOL Addinol HLP 46 Addinol HLPD 46 BP BP Energol HLP D 46 Energol HLP 46 CASTROL ELF Elfona 46 Hydr ELF 46 ESSO Nuto H 46 HOUGHTON Hydrolubric VG 46 MOBIL Mobil HLPD 46 X OEST Oest Hydrauliköl H LP 46 Hydrauliköl H LP 46 DD SHELL Shell Hydrol DO 46 Shell Tellus Öl 46 TEXACO Rondo Oil HD B 46 Alcor Oil DD 46 TOTAL Total Azolla ZS 46 TRIBOL Tribol 943 AW 46 ZELLER GMELIN ZET ...

Page 113: ...se gun grease type K 2 K Check the function of the central lubrication system daily The lubrication is correct when a very slight amount of surplus oil is lost under the table plate Oil Change The oil in the NC rotary table is to be changed after every 2000 operating hours or after one year at the latest Remove the drainage screw 3 and let the used oil run off into a suitable container Then screw ...

Page 114: ...e clamping jaws and the contact areas of the table plate with a feeler gauge The gap should measure between 0 1 and 0 2 mm In addition change the rubber stripper 10 on the covering plate 10a as soon as it shows signs of damage order number 106 14 50 03 Changing the Toothed Belt The NC rotary table s toothed belt must be changed if damaged Procedure First remove the main front cover 5 and loosen al...

Page 115: ...ys tighten the draw in bolts in the tool shaft Grease all tool shafts several times a week This way both fretting corrosion and a possible welding marks of shaft and spindle taper are avoided Only use the following type of grease for this Alltemp QNB from Klüber When changing tools manually insert the tool into the spindle carefully in order to avoid damaging the spindle taper Check that the tool ...

Page 116: ...uch measures and so the guideway strippers of this axis suffer greatly from wear Check the guideway stripper 1 every week for signs of wear Change the guideway stripper as soon as the first signs of wear are apparent If the guideway stripper three part has to be changed unscrew the 9 holding screws 2 and remove the worn stripper Clean the guideways thoroughly to remove oil dirt and swarf Mount the...

Page 117: ...st not be allowed to mix with it instead it should float on the surface It should be without any aggressive additives which can attack sealings paintwork tubing or guideways Note The following problems can arise from using the lubricantofthemakeBlaser CoAG Thecombination of lubricants for the slide ways or the addition of graphite and gray cast iron causes that the cooling lubricant turns brown wh...

Page 118: ... for the addresses of such companies locally In Germany emulsions with at least 4 oil content by weight are subject to the law on waste oil emulsions with lower oil contents to the law on general wastes Dealing with Cooling Lubricants The aggressive components in cooling lubricants can cause allergies and skin problems However by adhering to the following advice these can normally be avoided Avoid...

Page 119: ...e grade of deterioration of the surrounding air more often Unscrew the 6 holding screws 1 and take off the cover 2 Clean the heat exchanging element using compressed air without taking the element out In caseofoilyandstickypollution thecompleteelement can be taken off To achieve this unscrew the additional 4 holding screws 3 and take the element out Clean it in a bassin ...

Page 120: ...ourinoilinaccordancewith our recommendation on lubricants see chapter 5 Oil Change Carry out an oil change every year or after approx 2000 operating hours Removetheoildrainagescrew 3 onthebottomof the vertical milling head and allow the used oil to run out Allow the vertical milling head to remain so that as much of the used oil as possible can escape Screw the oil drainage screw 3 back in again a...

Page 121: ... the pressure reduction valve 1 counterclockwise inordertoreducethe pressure in the hydraulic system To refill hydraulic oil unscrew the cap 3 and fill the unit until the correct level is reached hydraulic oil see page 5 11 Changing the Hydraulic Oil Change the hydraulic oil yearly or every 2000 hours Remove the oil draining screw 4 on the front side of the unit and drain the used oil Replace the ...

Page 122: ...on valve 1 counterclockwise inordertoreducethe pressure in the hydraulic system Toexchangethefilter loosentheclampingscrews 5 of the cover 6 and take the cover off Afterthis thefilterunitwiththefilterelementcanbe takenout Makesure thatthesealingringbetween the filter unit and the cover is not lost Take the old filter element out and clean the filter unit thoroughly Insert the new filter element pa...

Page 123: ... supplies the drive with lubricant and carries off heat from the vertical milling head Topping up with Lubricating Oil Check the circulatory lubrication system s oil level every day The oil level must be visible at least in the middle of the inspection glass 1 In order to top up with lubricating oil unscrew and remove the lid of the storage tank and top up with lubricating oil in accordance with o...

Page 124: ...y 200 operating hours Completely unscrew the lid of the filter 5 17 mm wrench and remove the gauze filter Screw on the lid of the filter 5 immediately in order to avoid leakage of the storage tank Clean the filter by blowing though it or by washing it in a solvent Replace if the fabric of the filter is damaged Theheatvalve 6 hasbeensetto18 inthefactory and must not be changed The maximum ambient t...

Page 125: ...ht the spindle can be read up in chapter 9 of this manual 5 15 Rigid Clamping Table Maintenance 5 15 Rigid Clamping Table Maintenance The rigid clamping table requires little care or maintenance Care of the Table Surface If the rigid clamping table is not required for an extendedperiod e g weekend holidays etc clean the table thoroughly to remove dirt and swarf and wipe the table surface vigorousl...

Page 126: ...s absolutelysecurethecrossslide rest against falling down Movethecrosssliderestupwardsasfaraspossible so that the two screw threads M 12 beneath the cross slide rest become visible ScrewthetwohexagonsocketscrewsM12into the provided screw thread 1 at the machine column andletthecrosssliderestslowlyslidedownwards The cross slide rest is now secured against falling down Note Nomovementsuntilthescrews...

Page 127: ...urities fromthepipesandseparatesthecondensationwater from the compressed air Thelubricator 1 suppliesthecompressedairwithoil mist which is required to lubricate the pneumatic regulating and controlling devices 3 2 1 4 5 6 In order to refill new oil remove the oil charging screw 6 and top up with oil according to our lubricationrecommendation The oil metering screw 5 allows to regulate the refilled...

Page 128: ...GEAR SHIFTING cannot be performed correctely upthecontrolunitagain Selectspindle DEFECTIVE speed again In case the message appears again call our Service Department Screen Display The head is swivelled in and Swivel out the vertical head SWIVEL IN V HEAD M 29 is programmed Screen Display The head is swivelled out and Swivel in the vertical head SWIVEL OUT V HEAD M 29 is programmed Screen Display H...

Page 129: ...OSITION manually towards the spindle Position gripper 1 2 appropriately Screen Display Only in Service Help Activate key at the tool changer panel OPEN VALVE SPINDLE Screen Display Initiator flap not set Activate EMERGENCY STOP MOTOR up correctly or defective Call our Service Department FLAP FAULT Screen Display Tool call has been Before tool call VERTCAL HEAD QUILL programmed during Tilt back ver...

Page 130: ...ENCE INTERRUPT during TOOL CALL TOOL DEF NC Start sequence is continued PUSH NC START Tool sould be returned locking of cabin 1 2 open Screen Display Pneumatic look up missing Look uppneumatic PNEUMATICSYSTEM Screen Display Pass over reference points Select function RETRACTGRIPPER Screen Display Pass over reference points Select function TOOL CHANGER UNIT DOWN ...

Page 131: ...ADING STATION gripper 2 however place is manually to the selected place IS OCCUPIED occupied and take out tool manually Screen Display Magazine door open during Close magazine door CLOSE MAGAZINE TOOL CALL TOOL DEF activate NC Start DOOR or tool needs to be returned from gripper Screen Display Tool holder I II III not closed Close tool holders manually CLOSE TOOLHOLDER MAGAZINE Screen Display Malf...

Page 132: ...ge CENTRAL LUBE lubrication system runs for a Check the machine if there is any DEFECTIVE longer period than 1 minute oil leaking from it after a lubrication impuls has Switch on the control unit In case been initiated The pump can the message doesn t disappear call not build up the required our Service Department pressure Screen Display M06 has been programmed Insert tool manually See page 3 8 TO...

Page 133: ...RPM Screen Display Manual mode has not been Select manual mode CANGE TO MANUAL selected Help file is activated MODE and NC Start has been pushed Screen Display Help file is activated NC Start Select mode PGM FEED CODE NUMBER pushed and code number dial in code number not dialed in Screen Display Max temperature in one of the The control unit switches off the feed FEED MOTOR feed motors has been su...

Page 134: ...ting position SELECT HELP FILE 41 SELECT HELP FILE 41 and tool holder is closed Screen Display Vertical head needs to be Return tool into magazine T0 TAKE TOOL FROM swung off back however a tool SPINDLE is still in the spindle Screen Display Clear water tank of the filter Top up tank COOLANT LEVEL PURE fleece unit is not adequately Erase message with CE WATER TANK filled Pumps may not run dry Scre...

Page 135: ... error E R off switchonmachineagain Incasethe message doesn t disappear call our service department Screen Display Axle module defective EMERGENCY OFF mains switch FEED DRIVE off switchonthemachineagain Incase DEFEKTIVE the message doesn t disappear call our service department Screen Display Overload feed spindle Reduce load I2 t FEED DRIVE SPINDLE Screen Display Comunication NC PL faulty EMERGENC...

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