Zayer AF Milling machine 1

INDEX / INDEX / PAG.
INSTALLATION / INSTALLATION / INSTALLATION/ STARTING /

MACHINE CONTROLS / MAINTENANCE / MACHINE UNLOADING / FOUNDATION AND ANCHORAGE 

LUBRIFICATION 
Before startíng the machine, check if the order of the phases is correct .
1. Check wether the rotation direction of the milling head coincide with the corresponding position of the rotation switch of the motor.
2. Once the connection of the machine is done, push the button of the manual lubrification which is located on the automatic lubrication unit. If the connection is correct, the needle of the pressure gauge will show a pressure of 15 Kg/cm2 during a short time and will then go back to starting position. In the case the connection is not correct, the motor of the automatic lubrication unit will start working, but the needle of the pressure gauge will remain inmobile. In this case, change between them selves 2 of the 3 phases of the connection. When cleaning the machine, never use the following products: Benzene, Acetone or Toluene.

1 INSTALLATION
Necessary space and foundatíon. Foresee the space necessary according to drawing page 15. Prepare a cement base according to drawing pages 16-17. Such base must be vibration-proof and if it is possible isolated from the exterior.
Machine unloading. In order to realise the unloading of the machine, a 50 mm. Østeel bar will be used, as it is shown on drawing page 15, protecting machine parts that can be damaged by the slings with a cloth. Then, machine balance will be checked, correcting if necessary the slings position to achieve it, proceding to the unloading of the
machine with due precautions, specially at the moment of touching the machine base with the ground, so that this contact and later settlement is done gently and without collision. lnstallation on foundation and leveling. Place machine on cement base and mark its position on base through machine anchoring holes. Get off the machine then, and proceed to open the holes on base according to the marked position and to the drawing pages 16-1.
Afterwards, place the machine on the base together with the anchoring screws, plates and leveling screws, levelling out the machine aswell as possible and fill base holes with a  concrete mixture. When concrete is hard enough, proceed to definite levelling and once this is done tighten anchoring nuts strongly. Cleaning and lubrication. Once de above operations have been done, clean machine carefully removing the antirust grease which protects it, by means of petroleum and cloths, bearing in mind the VERY IMPORTANT WARNING about the cleaning see
page 2. Lubricate machine see page 18, checking machine oil levels 6
Electric connection.
A connection with an adequate cable section for the total comsumption of electricity of the machine should be prepared, placing between the mains and the machine at least some fuses, being preferable to use a switch with fuses.
2 Open the cabinet, to connect the connection in the general switch, once the connection is made, close the cabinet door and operate the general switch, in such a way that the switch handle be placed on position 1. 3 Proceed to check if the different machine elements work correctly, having in the VERY IMPORTANT WARNING
about the connection see page 2. If the machine have automatic lubrication equipment, press the lubrication button and check if the manometer Is pressurized and
works. If we see that there is no pressure, we shall disconnect the general switch from the machine, and also that one of the connection and we shall proceed to change two of the three inlet phases. Once this done, we shall do the same test and we shall check if we have pressure to effect the lubrication.

11 - STARTING
Once the machine is ready and the oil levels have been checked, proceed to the starting according to the following points:
a Loosen all blocking points.
b Connect intake current switch.
c Lubricate frame guides, knee and table, pushing the corresponding lubrication control.
d In case of starting spindle head, place inverses switch on position 1 or 2, according to the wanted rotation direction.
e Operate push-button corresponding to wanted movement.
lmportant warnings. Before starting, make sure all oil levels are on the half point of correspondent oil sight. Operate the lubrication drive on different positions of table, knee and ram. Machine is supplied with an alarm system in the event that it has automatic lubrication. This alarm is automatically connected when there is not oil left at all, in the lubrication. To stop the alarm, general stop push-button should be operated. When feed drive motor starts, without the automatic lubrication tank having been previously filled up, alarm will ring again. Keep daily attention to level of such lubricating group. Trial peclod operation is very important for the and good working of the machine. For the first 150 hours of work, use low speeds 890, are not to be passed.
Machine is provided of two ammeters, which show speeds motor current drain and feeds motor, respectively. In no case, the needle should pass the red mark on the ammeter.
Speed mechanism is provided with an electromagnetic brake that can be operated by the correspondent push-button. Its duty is to facilitate a quick stop of the spindle on special or emergency events. To operate spindle stop, machine general STOP must be used, having the precaution of stopping feeds first by the feeds STOP push-
button. This operation must be done specially on a hight feed, or working with rapid displacements.
When we may pretend to stop the head shaft through a break push-button, it must be activated on this one in a intermitent way and never havıng it pushed on a continuous way. When the machine is with displacements of one of its movements and it is pretended to invert it or to go to another different movement, is advisable before acting the push-button to stop first the working displacement that is in. This operation must be done specially when the feed is high or we are working on rapid displacements. In order to get the rapid traverse, it will be enough to operate rapid push-button and while we hold it pushed, displacement selected
before will work on rapid. On stopping pushing, such displacement will go back to the previously selected feed.
It is advisable not to abuse of rapid displacements for the first 300 hours of work.
Guideways will be runned in only after 300 hours of work on all their length.
111 - MACHINE CONTROLS
Push-buttons and handwheels. The machines have a control pannel on pendant control. Handwheels for manual displacements of machine, provided of corresponding graduated drums, are exactly double and they are
placed on the front and left side of the machine.
Brake vertical traverse. The machines are provided of ball screw in the vertical traverse, which due to its rare friction tents go down a little because of the knee and ram weights.
In order to avoid this phenomenon such ball-screw has been fitted in a brake that acts on the screw to prevent it going down.
This brake comes out from factory already regulated, however, if it would be necessary to increase the ball-screws brake, it would be operated as follows. The vertical traverse handwheel, is situated on the machine front and it has on its center the regulating control of brake tension; to
increase this tension, nut has to be loosen, turning to the right the pin in which such nut is placed and tension will be increased. After this operation, poceed to tighten nut.
7
Clamping mechanism. Machine is provided with clamps on the three movements. It is very important to check before operating any of the traverses, wheathel the corresponding clamps are on or not. Clamps for cross traverse are placed on top left part of knee and they are operated by two levers. Table clamping is done by the levers placed on front of the bed top. Vertical traverse clamping is done by side levers placed on the knee back part. Speeds change. They are done by the relative position of three levers, situated on the ram left side. Feeds are selected according to the table placed near the change controls. When trying to make a change of speeds, it will be done with motor stopped, a slight resistance of lever to go into its position will be
noticed. It will be enough to operate instantaneously speeds intermitent push-button, so that corresponding motor will turn in order to make easier the introduction of one gear into the other, and so, a change of speed will be achieved.
Head positions. By combining head and elbow rotation, the wanted inclination of the milling arbor can be obtained.
In order to do these rotations, it is necessary to losen slightly fixing nuts and take out positionning pins between ram and elbow and between the former and the head. Then, by introducing lever provided with the machine into corresponding head or elbow holes proceed to give the wanted position according to the tabulation enclosed in this instructions book. Before operations mentioned above, it will be necessary to check wheather speeds drive motor is stopped. Once wanted position has been obtained, fixing nuts will be tighten again. Usual positions. The usual milling positions are:
Spindle іn a vertical position.
Spindle in a row horizontal position. Both positions are given by conical pins, which insures the situation of the head-elbow assembly. Special care must be taken in
cleaning thoroughly these pins and introducing them, after placing head and elbow in correct position with the help of the vernier. Any swarf on the pins or the fact of knocking on the pins when the respective hole are not in Iine, can bring as a consequence the loosing of the exact position, and so, defects of machine verification. After introducing pins manually by means of the oscillation to both sides of head or elbow and after being pin wholy introduced and positioned, strike slightly such pin with a plastic hammer in
order to get an exact nailing of the wanted position. It is necessary to notice, that pins are provided of an extraction nut, which must be placed on pin in the wanted position before proceeding to the introduction of the pin.
1V - MAINTENANCE
Apart from following the instructions and recommendations already mentionned, it is necessary to study each case, the best arrangement of the part on the machine, avoiding that the biggest cutting or weight efforts of the part, if this is a large one, act or gravitate on the table parts which do not coincide with the machine central part or are off-center on its traverse trying so that the biggest efforts of cutting are done with the ram in a backwards position and they are not done in its most forward position. It has especial importance to lubricate periodically as it is shown on page 18, as well as to check the levels and oiling sights. Doing a regular cleaning of the machine avoids blocking of lubricating conveyors, it keeps its mobile parts without scratches or seizings and shows the workers neatness and order.
Motorized гam and universal head. Such elements need special attention for being machine parts of a great importance. The life of these parts is remarkably prolonged with a rational lubrication of these assemblies. It is advisable to drain and clean motorized ram every two months renewing oil according to the type shown on page 20. Spindle head bevel gears must be lubricated approx. every 15 days. The quantity of lubricating grease will not be excessive one or two strokes. Keeping this advise frequent lubrication and small quantity of grease, is very important to get a good efficiency of the head. The spindle head bearings must be lubricated every 200 working hours.
KLÜBER ISOFLEX NBU-15 is the only type of lubricating grease to be used in the planetary head. To get an efficient lubrication of the two conical gears in the planetary mobile-spindle, it will be necessary to disassembly the head
monthly, in order to impregnate such above conicals gears with KLÜBER ISOFLEX NBU-15 grease.
Feed drive motor. As feed drive motor is motor, it requires a monthly checking, easy to carry out and guaranteeing a correct performance of motor and absence of damages.
It must be observed in such check the condition of collector and brushes. Proceed to eliminate the dust produced by the brushes wear which can be espoused to motor collector with compressed air. If it is noticed on collector the existence of solid particles it must be proceeded to eliminate such particles by means of a cloth wet in petrol.
Brushes are subjected to wear and therefore they must be substituted periodically. In every checking brushes wear stage must be observed proceeding to their replacing when the distance between the matallic brush holder and motor collector be equal or less than 3 mm. As in another way it will rub directly the brush holder on the collector and
this will be spoiled. It is advisable to change all the motor brushes when a brush must be substituted. It must be noted on mounting the new brushes that these must be orientated radially to the motor shaft and also they must effect a
full contact with collector and because of this it can be proceeded to sandpaper the brush inserting the sandpaper between the collector and brush with the abrasive side directed towards the brush; sandpaper must tend to clasp the collector and in this position it is proceeded to displace atternateiy the sandpaper so brush tends to adjust its contact profile in accordance with collector diameter.
Greasing point mechanisms for cross and vertical movements transmission. Consistent grease KISSEL
transmissions mechanisme for longitudinal, vertical and cross movements. Consistent grease KISSEL
Greasing of the bearing in the main shaft of headstock. Every 200 hours. Oil sight for checking operation of the pump in the headstock. Sight for checking the oil level in the headstock. Sight for checking the oil level in automatic oiling system. Level lubrication tank for electro-clutches mechanisms. Niveau reservoir lubrication mecanisme electro-embrayages. Greasing point mechanisms for cross and vertical movements transmission. Consistent grease KISSEL. Greasing point manual transmissions mechanisme for longitudinal. vertıcal and cross movements. Consistent grease KISSEL
Every 15 days Lubrication.
Lubrication each 200 hours work.
Lubrication each 5000 hours work.
Oil level-check daily.
Stream-check daily.
Dropping-check daily.
Filter-change or clean every six months.
Oil level-check weekly.
Stream-check weekly.
Dropping-check weekly.
Filter-turn weekly.
Filter-change or clean yearly.
Speeds, feeds Manual and automatic lubrication Hydraulic clamping and compensator
Speeds, feeds manual and automatic lubrication hydraulic cIamping and Compensacor
Leveling: Table in central position.

Cross range: a Parallelism with the tabe. Clock
perpendicuIarity with the center slot of Square
the table. Deplacement transversal: a Parallelisme Comparateur. Vertical range a perpendicularity in and clock
4 e planes Square. Deplacement vertical: a Perpendicularite Comparateur
FICHA DE VERIFICACION
Spindle shaft: A axial movement of the clock spindle. Centering of taper. Centering boring of the spindle shaft near the taper and to a bar. Distande of 12 300 mm. Pendicularity of the spindle over the table.
Broche: A movement axial de 1 axel.

A Front horizontal position: a parallelism clock 6 between spindle axis with the surface of boring tool. The table. Perpendicularity between the spindle axis at the case slot of the position horizontale face. Horizontal position spindle to the right: a cock 7 check parallelism of the spindle axis with boring tool. The surface of the table. Parallelism of
the spindle axis with the central slot on the table. Position horizontale droite: a Parallelisme comparateur. Horizontal position of the spindle to the clock. Left: a check parallelism of the spindle boring tool. 8 axis with the surface of the table. Parallism of the spindle axis with the central u slot on the table. Position horizontale gauche. A parallelisme face de table. Parllelisme 
ZAYER UNIVERSAL HEAD
The spindle must be inclined in perpendicular planes to the
The spindle must be inclined on the A, B, C, D, plane, per- table screw A, B, C, D. There are them four different planes:
pendicular to the table and parallel to guideways. Spindle axis to the left and upwards. Just turn the elbow over the ram's plate, directly to the. Spindle axis to the right and upwards. Wanted angle looking at its position in the vernier. Spindle axis to the left and downwards. The head will keep always fixed for this first case, which. Spindle axis to the right and downwards. Vernier will coincide with 1800 graduation, not being necessary to use tabulation.
The spindie head must be placed on a horizontal plane A, B, C, D and A, B, E, F, parllel to the table and perpendicular to the frame guideways. This position is obtained by the combinated rotations of elbow and head, and it is used for the helix milling. This position of spindle axis is adequate for doing bevels of an angle of inclination equal in two sides of the piece perpendicular between them, by longitudinal
and cross displacements.
The operating way is as follows:
1. Known the angle H wanted, we will get the intermediate angle H1 on the tabulation.
2. Once known such intermediate angle H1, we will proceed, as in the rest of the cases, 10 find the correspondent degrees of vernier a and b by interpolation of
H1 value over H column.
3. It must be added or subtracted to vernier all value of degrees, the 90 H value.
4. We will proceed to put head according to degrees shown for our case on column b and the elbow according to the resultant degrees
Example:
For H= we have a value H1 = 71 07 or the tabulation. On column H, we get by interpolation a and b values correspondent to and which result respectively for spindle axis to the left incined downwards and for spindle axis to the right downwards inclined. Spindle axis to the left downwards inclined a values will be: Solutions: spindle axis to the right downwards inclined. General aplication of fourth case; on this one, the angles over piece faces are perpendicular between them, they are unequal.
The operating way is as follows:
1 We will get intermediate angle H1 by formula
2 We will proceed to get the degrees values for a and b verniers on a similar way as fourth case keeping in mind, that to position elbow to a value given on tabulation, it must be added or subtracted to it the 90 H value.
3 Example: on column H1, we get by interpolation a and b values correspondent to and which result respectively for spindle axis to the Ieft downwards inclined and for spindle axis to the right downwards inclined. All values will be: Solutions:
Spindle axis to the left
Downwards inclined
Spindle axis to the right
Downwards inclined