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OPERATION MANUAL

C O N T E N T S:

1. GENERAL MACHINE INFORMATION

1.1 Specifications.............................................................. 4

1.2 Identification............................................................... 5

1.3 Controls......................................................................... 6

2. SAFETY

2.1 General Metalworking Machine Safety............. 8

2.2 Specific Safety For Drill/Mill................................... 11

3. POWER SUPPLY

3.1 Eletrical Requirments............................................... 12

3.2 Full Load Current....................................................... 12

4. SETUP

4.1 Unpacking.................................................................... 13

4.2 Included Accessories................................................ 13

4.3 Clean Up........................................................................ 13

4.4 Site Preparation.......................................................... 14

4.5 Lifting Instructions.................................................... 14

4.6 Anchoring To The Floor............................................ 15

4.7 Machine Leveling...................................................... 15

4.8 Assembly....................................................................... 16

4.9 Checking Lubrication............................................... 17

4.10 Test Run......................................................................... 17

5. OPERATION

5.1 Operation Overview................................................. 19

5.2 Headstock Movement.............................................. 20

5.3 Spindle Movement.................................................... 21

5.4 Setting Up For Tapping............................................ 22

5.5 Table Movement........................................................ 23

5.6 Installing And Removing The Tooling................ 24

5.7 Changing The Speed................................................ 25

6. MAINTENANCE

6.1 Lubrication................................................................... 26

6.2 Changing The Gearbox Oil..................................... 26

6.3 Gib Adjustment.......................................................... 27

6.4 Troubleshooting........................................................ 28

Spare Parts............................................................................ 29

Risk Assessment Sheets................................................... 36

Содержание Metalmaster DMF-44

Страница 1: ...OPERATION MANUAL Edition No DMF 44 1 Date of Issue 07 2020 Model DMF 44 Order Code D185 PEDESTAL MILL DRILL ...

Страница 2: ...MACHINE DMF 44 MODEL NO SERIAL NO DATE OF MANF NOTE This manual is only for your reference Owing to the continuous improvement of the Hafco Metalmaster machine changes may be made at any time without obligation or notice Please ensure the local voltage is the same as listed on the specification plate before operating this electric machine Distributed by www machineryhouse co nz MACHINE DETAILS ...

Страница 3: ...Clean Up 13 4 4 Site Preparation 14 4 5 Lifting Instructions 14 4 6 Anchoring To The Floor 15 4 7 Machine Leveling 15 4 8 Assembly 16 4 9 Checking Lubrication 17 4 10 Test Run 17 5 OPERATION 5 1 Operation Overview 19 5 2 Headstock Movement 20 5 3 Spindle Movement 21 5 4 Setting Up For Tapping 22 5 5 Table Movement 23 5 6 Installing And Removing The Tooling 24 5 7 Changing The Speed 25 6 MAINTENANC...

Страница 4: ...mm 850 Type of Slides Dovetail Spindle to Table mm 630 Spindle Travel mm 120 Spindle Diameter mm Ø75 Throat Depth max mm 280 Tilting Head Left Right 90º Drilling Capacity mm 31 5 Drilling Capacity mm 28 Face Milling Capacity mm 80 Table T Slot Size mm 14 Work Table Load Capacity kg 55 Spindle Speeds No rpm 6 95 1650 Motor Power kW hp 1 5 2 Voltage Amperage V amp 240 10 Dimensions H x W x D cm 1760...

Страница 5: ...gitudinal Travel Hand wheel B Head I Vertical Travel Handle C Motor J Base D Speed Selection Levers K Coolant Pump E Fine Spindle Feed L Cross Travel Hand wheel F Course Spindle Feed M Spindle G Slotted Table N Cutter Safety Guard A B C E D F G G H I J K L N M ...

Страница 6: ...tely stopped before this button is pushed Fig 4 1 B DRILL OR TAP SELECTOR Selects either a drilling or tapping option When tap is selected the spindle reverses when it reaches the depth stop C POWER Lamp Illuminates when the machine is connected to power D REVERSE Button Starts counter clock wise spindle rotation as viewed from above The spindle must be completely stopped before this button is pus...

Страница 7: ...g 4 3 2 Loosen down feed selector knob E to engage coarse down feed handles 3 Position depth stop with adjustment knob C 4 Use coarse down feed handles to raise and lower the spindle F To Use The Fine Down Feed 1 Loosen quill lock lever 2 Tighten down feed selector knob to engage fine down feed hand wheel 3 Position depth stop with adjustment knob 4 Rotate fine down feed hand wheel to raise and lo...

Страница 8: ...e equipment The manufacturer will not be held liable for injury or property damage from negligence improper training machine modifications or misuse WARNING 2 1 GENERAL METALWORKING MACHINE SAFETY Always wear safety glasses or goggles Wear appropriate safety footwear Wear respiratory protection where required Gloves should never be worn while operating the machine and only worn when handling the w...

Страница 9: ...und the machine to do the job safely Obtain first aid immediately for all injuries Understand that the health and fire hazards can vary from material to material Make sure all appropriate precautions are taken Clean machines and the surrounding area when the operation is finished Use proper lock out procedures when servicing or cleaning the machines or power tools DO NOT Do not distract an operato...

Страница 10: ...s etc Biological contamination and waste Soft tissue injuries for example to the hands arms shoulders back or neck resulting from repetitive motion awkward posture extended lifting and pressure grip Other Hazards Slips and falls from and around machinery during maintenance Unstable equipment that is not secured against falling over Safe access to from machines access egress Fire or explosion Press...

Страница 11: ...olant delivery system to allow for sufficient flow of coolant OPERATIONAL SAFETY CHECKS Keep clear of moving machine parts Follow correct clamping procedures Keep overhangs as small as possible and check to make sure that the cutter will not be impeded by the clamps Set the correct speed to suit the cutter diameter the depth of cut and the material Ensure the cutter is clear of the workpiece befor...

Страница 12: ...cuitry This is especially true if connected to an undersized circuit or a long extension lead To reduce the risk of these hazards avoid overloading the machine during operation and make sure it is connected to a power supply circuit that meets the requirements 3 2 FULL LOAD CURRENT RATING Place the machine near an existing power source Make sure all power cords are protected from traffic material ...

Страница 13: ...k or taper shank drills q 1 x M12 x 1 75mm draw bar q 1 x 1 2 x 12TPI draw bar q Safety cutter guard Not Shown When unpacking the machine check the accessories against the list below The unpainted surfaces of the machine have been coated with a waxy oil to protect them from corrosion during shipment Remove the protective coating with a solvent cleaner or a citrus based degreaser Optimum performanc...

Страница 14: ...city is avail able to unload the machine from the vehicle Ensure access to the chosen site is clear and that doors and ceilings are sufficiently high and wide enough to receive the machine This machine is extremely heavy Serious personal injury may occur if safe moving methods are not followed To be safe you will need assistance and power equip ment when moving the shipping crate and removing the ...

Страница 15: ...mple in Fig 4 4 Fig 4 4 Fig 4 3 4 7 MACHINE LEVELING To set your machine up so that it operates to optimum performance the machine should be level To level the machine follow the procedure below After your machine has been anchored to a concrete slab floor then the leveling is performed by loosening the hold down bolts and then inserting metal shims under each hold down bolt until the machine is l...

Страница 16: ...hat raises the table making sure that the set screw is lined up with the dimple on the shaft When the set screw is lined up tighten the screw Fig 4 6 2 Mount the cross travel and longitudinal hand wheels to the shafts and tighten socket head cap screws and the washers to the shafts Fig 4 7 Fig 4 6 Set Screw Fig 4 7 Set Screw Socket Head Cap Screw 3 Install the three coarse down feed handles onto t...

Страница 17: ...em BEFORE operating the machine again Consult The Troubleshooting table in the maintenance section of this manual for possible solution The Test Run consists of verifying the following 1 The motor powers up and runs correctly and 2 the safety disabling mechanism on the emergency stop button works correctly 3 Cutter Safety Guard limit switch works correctly To test run the mill drill 1 Clear all se...

Страница 18: ...utton press SPINDLE FORWARD button Machine should not start NOTE If the machine does start with EMERGENCY STOP button pushed in immediately disconnect the power to machine as EMERGENCY STOP safety feature is not working correctly This safety feature must work properly before proceeding with regular operations Refer to Troubleshooting on Page 28 for possible solution Fig 4 11 12 Twist EMERGENCY STO...

Страница 19: ...eeds to do the following 1 Examines the workpiece to make sure it is suitable for the machining operation 2 Check the machine to ensure that it is safe to use and put on protective clothing and safety equipment 3 Place the workpiece on the table and securely clamp it to the table 4 Select the correct cutting tool for the job and with the machine disconnected from power install the cutting tool usi...

Страница 20: ...is one on either side of the head Fig 5 3 and one under the bottom of the head see Fig 5 4 NOTE The 3 nuts must only be loosened a quarter to a half a turn maximum to avoid the head disengaging from the tilting mechanism and the head dropping under its own weight 3 Using the scale shown as a guide swivel the headstock and re tighten the three hex nuts to secure it 3 Use Z axis crank shown in Fig 5...

Страница 21: ...r knob A in Fig 5 5 USING FINE DOWN FEED Fine down feed is typically used when precise vertical positioning of an end mill or cutter is used when milling a flat surface across the face of a workpiece The fine down feed hand wheel Fig 5 6 is equipped with a graduated collar with 0 025mm increments Each complete revolution of the hand wheel equals 0 250mm After each adjustment the quill lock lever F...

Страница 22: ... 5 8 making sure that the tap does not bottom out 3 Adjust the depth stop by turning the knurled knob A in Fig 5 9 accordingly 4 Apply some tapping fluid to the contact point of the tap and to the workpiece 5 Connect the machine to power 6 Select the tapping mode with the drilling tapping switch on the control panel Fig 5 10 7 Select the appropriate spindle speed Speeds vary according to the type ...

Страница 23: ...vides so the graduated dial can be adjusted to a relative starting point Fig 5 12 Fig 5 13 Fig 5 12 Cross Dial Fig 5 13 Longitudinal Dial Before moving the table make sure that the table lock for that movement has been unlocked Always lock the table if not using the movement in that direction Fig 5 14 NOTE WHEN TIGHTENED TABLE LOCKS PROVIDE TABLE RIGIDITY IN THAT PATH OF TABLE TRAVEL FOR INCREASED...

Страница 24: ...bor 4 Working from the top thread the draw bar by hand into the tooling until it is snug then use a spanner to tighten it 5 Replace the draw bar cap To remove the tooling 1 DISCONNECT THE MACHINE FROM POWER 2 Remove the draw bar cap 3 Un thread the draw bar from tooling one full rotation NOTE DO NOT FULLY UN THREAD THE TOOLING FROM THE DRAW BAR OR THE DRAW BAR AND TOOL THREADS COULD BE DAMAGED IN ...

Страница 25: ... produce the desired finish and optimize tool life Books such as Fitting and Machinery Technical Manual L341 or Machine Shop Practice and some Internet sites provide excellent recommendations for which cutting speeds to use when calculating the spindle speed These sources also provide a wealth of additional information about the variables that affect cutting speed and they are a good educational r...

Страница 26: ...The gear box should be filled with oil such as SAE 68 to the level in the sight glass CHANGE OIL EVERY 12 MONTHS 5 Apply oil to quill pinion EVERY 90 DAYS NOTE Use extreme care when performing these operations and keep hands clear of pinch points Do not apply with motor running 6 2 CHANGING THE GEAR BOX OIL The headstock oil should be changed every 12 months To Change The Oil 1 Run the spindle for...

Страница 27: ... or decrease the friction pressure between the sliding surfaces The process of properly adjusting the gibs requires trial and error and patience Refer to Fig 6 3 6 4 to identify the locations of the table and saddle and one of the two adjustment screws for each NOTE It will be necessary to remove small parts such as way wipers and covers to access the gib adjustment screws The following is the met...

Страница 28: ...Tighten quill lock lever 6 Tighten gibs Table is hard to move 1 Table locks are tightened down 2 Chips have loaded up on ways 3 Ways are dry and need lubrication 4 Table limit stops are interfering 5 Gibs are too tight 1 Fully release table locks 2 Frequently clean away chips or debris 3 Lubricate ways 4 Make sure that table limit stops are not in the way 5 Adjust gibs Headstock is hard to raise 1...

Страница 29: ...rent at the time this manual was originally printed Due to continuous improvements of the machine changes may be made at any time without notification HOW TO ORDER SPARE PARTS 1 Have your machines model number serial number date of manufacture on hand these can be found on the specification plate mounted on the machine 2 A scanned copy of your parts list diagram with required spare part s identifi...

Страница 30: ...30 OPERATION MANUAL 240V WIRING DIAGRAM ...

Страница 31: ...31 OPERATION MANUAL DMF 44 HEAD SPARE PARTS DIAGRAM NOTE SOME INDIVIDUAL PARTS MAY ONLY BE AVAILABLE AS AN ASSEMBLY ...

Страница 32: ... 20111 B GEAR Z21 20106 1 B GEAR Z41 6202 P5 BEARING 1 1 2 2 1 2 1 1 1 1 1 1 6 2 1 1 1 1 2 2 2 1 3 6 1 1 1 3 3 1 1 1 1 1 1 4 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 6X14 KEY 6X28 KEY Ø 8 BALL SPRING Ø18 EXT RETAINING RING 5X50 KEY M6X12 SCREW 20107B III SHAFT 20109 B GEAR Z25 20110 2 B GEAR Z18 20112 B GEAR Z32 20113 B GEAR Z43 20...

Страница 33: ...121B HANDLE ROD 20301B HANDLE BALL 20306B HANDLE WHEEL 20305 B HANDLE ROD M8X25 SCREW 10107 SCREW 203063 WASHER 203066 SCREW M6X12 SCREW M5X12 SCREW 3X12 PIN 8X20 KEY M5X20 SCREW 3X15 PIN 20124B FIXED BOLT 20203B FIXED TIGHT BLOCK 20202B FIXED TIGHT BLOCK 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 3 1 2 1 2 1 1 1 1 108 109 110 111 112 113 114 115 116 117 118 119 ADJUST HANDLE 20125B LEVER...

Страница 34: ...34 OPERATION MANUAL DMF 44 TABLE COLUMN SPARE PARTS DIAGRAM NOTE SOME INDIVIDUAL PARTS MAY ONLY BE AVAILABLE AS AN ASSEMBLY ...

Страница 35: ...ION PLATE 10301 40 HANDWHEEL 20305 2B 40 SCREW 20305 1B 40 TURN HANDLE ADJUST HANDLE OIL CUP8 PIN 5X35 10107 40 SCREW 10105 40 FIXED BLOCK SCREW M8 X 16 SCREW M5 X 25 SCREW M8 X 45 SCREW M5 X 25 SCREW M8 X 20 BOLT M14 X 60 LOCK WASHER 14 FLAT WASHER 14 FLAT WASHER 16 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 4 1 1 2 1 3 3 3 3 3 3 3 3 1 2 1 1 1 8 4 4 6 2 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 ...

Страница 36: ...n the off position before re connecting 14 Use correct amperage extension cords Undersized extension cords overheat and lose power Replace extension cords if they become damaged 15 Keep machine well maintained Keep blades sharp and clean for best and safest performance Follow instructions when lubricating and changing accessories 16 Keep machine well guarded Make sure guards on machine are in plac...

Страница 37: ...ly in place 8 Cutting Tool inspection Inspect Drill and end mills for sharpness chips or cracks before use Replace any cutting tools immediately if dull chipped or cracked Handle new cutting tools with care Cutting edges are very sharp and can cause lacerations 9 Reversing the spindle Make sure the spindle has come to a complete stop before changing the direction of the spindle Do not slow or stop...

Страница 38: ...workpiece on mill table MEDIUM Eliminate avoid loose clothing Long hair etc Incorrect adjustment may result in the head becoming detatched and a crushing hazard Mill head tilting adjustment please refer to mill head tilting instruction sheet for correct procedure Make sure all guards are secured shut when machine is on HIGH MEDIUM Ensure correct spindle direction when milling Ensure tooling is sec...

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