Zayer MF CM Milling machine

ZAYER MF CM 

INSTALLATION PLAN 
- START-UP 
- MACHINE CONTROLS 
- PREVENTIVE MAINTENANCE 
- REQUIRED SPACE 
- LUBRICATION
  - LUBRICATION SYMBOL SHEET 
  - OIL EQUIVALENCE TABLE 
  - TEST SHEET 
- ZAYER UNIVERSAL HEAD - INCLINATION TABLES
  - FIRST CASE .
  - SECOND CASE 
  - THIRD CASE 
  - FOURTH CASE .
  - FIFTH CASE 

Before starting the machine, check with a phasemeter if the order of the phases is correct, looking from left to right at the power inlet of the regulator.

Practical ways to perform this check, if a phasemeter is not available:
1. Verify that the rotation direction of the milling head matches the corresponding position of the motor's rotation selector.
2. After connecting the machine, press the button for manual lubrication located on the automatic lubrication unit.
If the connection is correct, the pressure gauge needle will briefly show a pressure of 15 Kg/cm2 and then return to the initial position.
If the connection is incorrect, the motor of the automatic lubrication unit will run, but the pressure gauge needle will remain still.
In this case, interchange two of the three phases of the supply.
When cleaning the machine, do not use the following products: benzene, acetone, toluene.

This translation covers the index of the document along with the specific note regarding machine start-up and safety checks. If you have any more sections or specific parts that need translation or further assistance, feel free to ask!

1 - INSTALLATION
Necessary space and foundation. Foresee the space necessary according to drawing page 11. Prepare a cement base according to the attached drawing. Such base must be vibration-proof and if it is possible isolated from the exterior. lnstallation on foundatíon and levelíng. 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 attached drawing.
Afterwards, place the machine on the base together with the anchoring screws, plates and leveling screws, levelling out the
machine as well as possible and fill base holes with a concrete mixture.
When concrete is hard enough, proceed to definite levelling and once this is done tíghten anchoring nuts strongly.
Cleaníng and lubrícatíon. 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 seepage 2 .
Lubricate machine see pages 12-13 , checking machine oil levels.
Electríc connectíon.
1. 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 ìn 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 mind the VERY 1MPORTANT WARNING about the connection see page 2 .
1f 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 sha11 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 Connect intake current switch.
b Lubricate frame guides, knee and bed, pushing the corresponding lubrication control.
c  case of starting spindle head, place inverses switch on position 1 or 2, according to the wanted rotation direction.
d Operate push-button correspondíng to wanted movement.
lmportant warníngs. Before starting, make sure all oil evels are on the half point of correspondent oil sight. Operate the lubrication drive on dífferent positions of bed, 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 period operation is very important for the life and good working of the machine.
For the first 150 hours of work, use 1ow speeds890 г, are not to be passed.
Machine is provided of two ammeters, which show speeds motor current drain and feeds motor, respectívely. 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, machíne 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.
In order to get the rapid traverse, it wil 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 fìrst 300 hours of work.
Guídeways will be runned in only after 300 hours of work on all their length.
MACHINE CONTROLS
Push-buttons and handwheels. The machines have a control pannel, on the left side of the machine or on pendant control.
Handwheels for manual displacements of machine, províded of corresponding graduated drums, are placed on the left side of the machine.
Brake vertícal traverse. The machines are provided of ball-screw ín 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, iıf it would be necessary to increase the ball-screw brake, it would be operated as follows.
The vertical traverse handwheel is situated on the left síde of the machine and it has on ìts center the regulating control of brake tensíon; 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, proceed to tighten nut.
Clampíng mechanísm. Machine is provided with hydraulic clampings on the three movements.
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 tryíng 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 speds 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 millíng arbor can be obtained.
Iп order to do these rotations, it is necessary to losen slightly fixing nuts and take out positionning pins between ram and elbowand between the former and the head. Then, by introducing lever províded with the machine into corresponding head or elbow holes proceed to give the wanted position according to the tabulatíon enclosed in this instructions book.
Before the operations mentioned above, it will be necessary to check wheather speeds drive motor is stopped.
Once wanted position has been obtaìned, fixing nuts will be tighten again.
Usual posítíons. The usual milling positions are:
Spindle in a vertical position.
Spindle in a low horizontal position.
Both positions are given by conical pins, which insures the situation of the head-elbow assembly. Special caгe must be taken in cleaning thoroughly these pins and introducting them, after placing head and elbow in correct position wíth 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 line, can bring as a consequence the loosing of the exact position, and so, defects of machine verification. After introducíng pins manually by means of the oscillatíon 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, 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 positìon.
1t has special importance to lubricate periodically as it is shown on pages 12-13, as well as to check the 1evels and oiling sights.
Doing a regular cleaníng of the machine avoids blocking of lubricating conveyors, it keeps its mobile parts wíthout scratches or seizings and shows the worker s neatness and order.
Motorízed ram 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 15.
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 thís 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.
KLŰBER 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 ímpregnate such above conícals gears with KLÜBER ISOFLEX NBU-15 grease.
Spindle shaft. a Axíal movement of the Clock.
spindle. b Centeríng of taper. c Centeríng Boring bar. 0,01 mm.
of the spíndle near the tapér and to a dís- Baг.
tance of 12 300 mm. from the goingout. 0,01 mm.
7 c d Perpendicularity of the spíndle over the table. Three posítions d, e, f 0,02 mm.
a Spindle axis paгa11e1 to the additiona1
- - maгЬ1e surface. Comparador Mandril
ь spindle axis para11e1ism respectively to
the para11e1 p1ane to longítudínal Ct1roac-k-Chuck.
verse.
The spindle must be inclined in perpendicular pFaπes to the
The spindle must be inclined on the A, B, C, D, p1ane, per- tab1e screw A, B, C, D. There are them four dífferent planes:
pendicular to the table and para11e1 to guideways. 1. Spindle axis to the left and upwards.
Just turn the elbow over the ram s plate, directiy to the 2. Spíndle axís to the right and upwards.
wanted angle H looking at its positíon in the vernier a1. 3. Spindle axis to the left and downwards.
The head wi11 keep always fixed for this first case, whìch b 4. Spindle axis to the right and downwards.
vernier wi11 coincide with 180 graduation, not being
necessaτy to use tabulation.
Milling arbor must be placed on a bisector p1ane of A, B, C, D and E, B, C, F planes.
This position of spindle axis is adequate for doing bevels of an angle of inclination H equal in two sides of the piece perpendicular between them, by longítudinal
and cross displacements.
The operating way is as follows:
1. Known the angle H wanted, we wi11 get the intermediate angle H1 on the tabulatíon.
2. Once known such intermediate angle H1, we wi11 proceed, as in the rest of the cases, to find the correspondent degrees of vernier a and b by interpolation of
H1 vυlue over H column.
3. 1t must Ьe added or subtracted to vernier a value of degrees, the 90 H va1ue.
4. We wi11 proceed to pue head according to degrees shown for our case on column b and the elbow according to the resultant degrees of a+ 90 H oг a
90 H1.
Example:
For H= we have a value H1 = 71 07 on the tabulation. On column H, we get by ínterpolation a and b values correspondent to 71 07 and whích result respec-
tívely a= 315 38 ; Ь= 1100 39 for spindle axìs to the left inclined downwards and a= 440 22 ; Ь= 249 21 for spíndle axís to the right downwards inclined.
315 38 + 90 70 = 335 38 1. a= 3350 38 b= 110 39 Spíndle axís to the left
315 38 90 70 = 295 38 2. a= 295 38 Ь= 110 39 downwards inclined a values wi11 be: Solutions: 44 22 + 90 70 = 64 22 3. a= 64 22 Ь= 249 21 Spindle axis to the right
44 22 900 -- 70 = 24 22 4. a= 24 22 Ь= 249 21 downwards inclined
General aplication of fourth case; oп thís one, the angles over piece faces are perpendicular between them, they are unequal.
The operating way ís as follows:
1 We wí11 get íntermedíate angle H1 by formula
 We wi11 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:
0n column H1, we get by interpolation a and bİ .,i s correspondent to 60 22 and whích result respectively a= 305 34; Ь= 90 38 for spindle axis to the left
downwards inclined and a= 54 26 ; Ь =269 22 tur . нnd1e axis to the right downwards inclined.
a values wi11 be: Solutю s.
305 34 + 90 80 = 315 34 1. a 315 34 Ь= 90 38 Spindle axis to the left
305 34 90 80 = 295 34 2. a= 295 34 Ь= 90 38 downwards incIined
54 26 + 90 80 = 64 26 З. a= 64 26 Ь= 269 22 Spindle axis to the right
540 26 90 80 1= 44 26 4. a= 440 26 b= 269 22 downwaŕds inclined