Technical sheets C 40• • • • • Designated use General safety regulations General Technical data Transport and installation Machine dimensions and machine weight Version: 12 - EN II Table of Contents Table of Contents Table of Contents .............................................................................................................. III Designated use ................................................................................................................ Intended use ..................................................................................................................... Dry machining and machining with minimum quantity lubrication ..................................... Qualification ...................................................................................................................... Troubleshooting................................................................................................................. Duty to inform .................................................................................................................... Documentation overview ................................................................................................... Disposal ............................................................................................................................ Not designated use ........................................................................................................... 1 2 2 3 4 4 5 6 7 General safety regulations ............................................................................................. General ............................................................................................................................. Operational safety ............................................................................................................. Equipment and installation safety ..................................................................................... Safety during repair work .................................................................................................. Environmental safety ......................................................................................................... Gravity-loaded axes .......................................................................................................... Manual unlocking of the cabin door in case of emergency ............................................... 9 10 12 14 15 17 18 19 General technical data .................................................................................................... Feed drive ......................................................................................................................... Traverse range .................................................................................................................. Positioning accuracy ......................................................................................................... Measuring system ............................................................................................................. Lighting .............................................................................................................................. Noise level ......................................................................................................................... Electrical connection ......................................................................................................... Electrics machine ............................................................................................................. Electrical system internal coolant supply ......................................................................... Operating conditions for electrical equipment ................................................................... Pneumatic system ............................................................................................................. Cooling lubricant ............................................................................................................... Designation of the machine axes ...................................................................................... Data transfer ..................................................................................................................... Data backup ...................................................................................................................... 21 22 22 22 23 23 23 24 25 25 26 27 29 31 32 32 III Table of Contents Transport and installation .............................................................................................. General transport regulations ............................................................................................ General safety instructions ................................................................................................ Information on the transport in a packing case ................................................................. C 30 Transport weight ....................................................................................................... C 30 Transport dimensions ............................................................................................... C 30 Transport centre of gravity ........................................................................................ C 40 Transport weight ....................................................................................................... C 40 Transport dimensions ............................................................................................... C 40 Transport centre of gravity ........................................................................................ Anchor points for securing the load ................................................................................... Transport information ........................................................................................................ Storage information ........................................................................................................... Preparations related to the machine location .................................................................... Preconditions for commissioning ...................................................................................... Preparations for commissioning ........................................................................................ Electrical connection ......................................................................................................... Pneumatic connection ....................................................................................................... Arrangement of the precision pads ................................................................................... Transport by fork lift truck .................................................................................................. Transport by crane ............................................................................................................ Transport by heavy load rollers ......................................................................................... Machine from the floor onto the heavy load rollers ........................................................... Machine from the heavy load rollers onto the precision pads ........................................... Transport of the additional magazines ZM 43 and ZM 87 ................................................. Transport of the additional magazine ZM 157 ................................................................... 33 34 36 37 40 40 41 42 42 43 44 45 46 47 50 51 52 54 55 56 62 69 70 71 78 85 Machine dimensions and machine weight ................................................................... C 30 Machine dimension ................................................................................................... C 30 Machine weight ......................................................................................................... C 30 Static load of standard machine ............................................................................... C 30 Dynamic load of standard machine .......................................................................... C 40 Machine dimension ................................................................................................... C 40 Machine weight ......................................................................................................... C 40 Static load of standard machine ............................................................................... C 40 Dynamic load of standard machine .......................................................................... Instructions for measuring the evenness of the surface at the machine location (C 30, C 40) ....................................................................................................................... C 30 Dimension sheet for surface evenness at machine location .................................... C 40 Dimension sheet for surface evenness at machine location .................................... IV 101 102 104 104 105 106 108 108 109 111 113 115 Chapter Designated use 1 Designated use Intended use Machining (according to DIN 8589 part 0) by means of rotating tools with at least one geometrically defined edge. The following machining operations are possible: • Milling (according to DIN 8589 T3: Face milling, round milling, screw milling, gearhobbing, profile cutting, form cutting) • Drilling (according to DIN 8589 T2: end facing, round drilling, screw drilling, profile drilling, form drilling) Materials: Metal, wood and plastics. Do not machine materials containing magnesium. Cooling lubricants: No cooling lubricants containing more than 15% by volume of inflammable liquid (e.g. oil). Tools: Use only tools dimensioned and balanced adequately for the speed and metal removing capacity required (see the manufacturer's specifications and the chapter "Milling spindle"). Dry machining and machining with minimum quantity lubrication According to the machining process and the material besides the free-falling swarf also fine swarf (metallic dust) is produced, which is not bound or discharged by a cooling lubricant. When the amount of swarf is large, it must be extracted via a special working area extraction and must be separated by means of a filter. In the light alloy processing (e.g. aluminium) with a very large amount of fine swarf being produced, also a possible exothermal reaction has to be taken into account. In this case, appropriate fire protection and explosion prevention must necessarily be provided. In any case a swarf accumulation in the working area of the machining centre should be avoided (clean the working area within suitable intervals). Examples of inflammable and explosive materials: • Organic, natural dust from coal and wood • Inorganic dust from magnesium, aluminium, or zinc 2 Keep unauthorized persons outside of the danger area during machine installation and commissioning! The instructions in the chapter "Transport and installation" must be followed! Repositioning of the machine Repositioning of the machine from one installation site to another: The repositioning of the machine may only be performed by sufficiently qualified personnel. Conversion Conversions and modifications of the machine: Exclusively by the Hermle AG Customer Service or a service authorized by Hermle AG. Maintenance (cleaning. The machine may only be adjusted by one person! To avoid that two people put each other in a dangerous situation. Follow the instructions in the Hermle operating manual. controlling): Especially trained personnel. the Hermle AG Customer Service or a service authorized by the Hermle AG must be contacted. Follow the instructions in the Hermle operating manual. supplementing and exchanging consumables and process materials): Especially trained personnel. lubricating. Hermle AG: The installation of the machine may only be performed by sufficiently qualified personnel. Prior to a repositioning of the machine. the adjustment of the machine must not be done by two or more people at the same time. Hermle AG will decline any liability or warranty for machine damage caused by incorrect repositioning of the machine Qualification 3 . Maintenance Inspection (measuring. repairs): Exclusively by the Hermle AG Customer Service or a service authorized by Hermle AG.Designated use Operation Setup. Service (exchanging parts. He must confirm the instruction in writing. The owner of the machine is obligated to inform its personnel about the specific risks on the basis of the operating manual. and commissioning of the machine only by the Hermle AG Customer Service or a service authorized by Hermle AG. Machine installation and start-up Installation and start-up of the machine after being delivered ex works. process monitoring. loading: Only personnel especially trained on the machine. checking. 4 . shut down the machine immediately (press Emergency Stop device). the owner has to make sure that the operating manual was read and understood by the relevant personnel. the general accident prevention regulations of the relevant professional association must be heeded. Duty to inform Before putting the machine into operation. In addition. noise and obvious faults to your superior and note them in the workbook. In case of danger.Designated use Troubleshooting Report any irregularities. The user documentation is intended for the owner of the machine and is subject to the CE conformity. Skilled employees must be able to evaluate the work that has been assigned to them and to recognize and eliminate potential hazards. The service documentation contains the following documents: • Spare parts diagrams – Hydraulic. maintenance and inspection).Designated use The Hermle machine documentation has been prepared for qualified employees and consists of the user and service documentation. pneumatic. A skilled employee (expert) is anyone who. by virtue of his/her specialist training and experience in the handling of machine tools (regarding operation. cooling lubricant and lubrication diagrams – Drawings of spare parts and wearing parts • Electrical circuit diagrams • Technical documents of the ancillary equipment (including consumables) • User Manual Collection (Siemens) Documentation overview . The user documentation contains the following documents: • Handbooks of the control unit • Hermle operating manual (standard) • Ordering forms for ordering the access codes for the "Optional Mode" • Error messages • Hermle operating manual for special constructions (if available) • Operating manual for the tool management system TCS software (if available) • Working area plans • Service record The service documentation is intended exclusively for the Hermle AG customer service or the service authorized by Hermle AG and is not subject to CE conformity. has good knowledge in this technical field. .Designated use Disposal At the end of their service life. the disposal of the components (consumables and subassemblies) must be carried in accordance with the regulations of the country in question and in accordance with regional or local provisions. Proper disposal of the components (operating materials and assemblies) does not cause any hazards to people or damage to the environment. If recycling is not possible. We recommend you to contact a company specialized in waste disposal. the individual components (consumables and subassemblies) of the machine must be passed on to the appropriate recycling process. – Use of unbriefed or inadequately trained personnel. – Machining with grinding or separating plates. protective cabin on pallet changer) by third parties. e.g.g. Examples of possible incorrect applications and prohibited operating modes: – Bypassing or removing safety devices. Not designated use . separating protective cover after repairs or disabling the safety switch on the cabin door with an alternative actuator for reasons of convenience. – Using flammable cooling lubricants.g. If the designated use is changed due to incorrect applications or prohibited operating modes. risk of an explosive gas reaction when magnesium comes into contact with water. for troubleshooting purposes.g. Such improper use is to be avoided at all times. The protective capability of the machine housing is not designed to withstand grinding tool breakages. Incorrect applications and prohibited operating modes are to be avoided. – Machining substances that contain magnesium. – Intentional misuse by stepping over or crawling under protective devices (e. e.Designated use Any deviation from the designated use specified can cause injury or death. increased risk of fire and explosion due to atomisation of the cutting oil during processing. – Deliberate shutting of personnel behind protective equipment (e. photoelectric light barrier in the working area of the PW 2000 pallet changer is bypassed by stepping over it or crawling under it). resulting in formation of an explosive dust and air mixture. risk of fragments being thrown out if the grinding tool breaks. not refitting a solid. e. e.g.g.g. – The installation of machine in a hazardous (explosive) environment. e. operator has no access to operating manual. this can cause hazards that are not covered by the machine's safety features. – Dry machining or machining with minimum quantity lubrication without adequate extraction. e.g. Designated use . Chapter General safety regulations 9 . protective clothing and safety gloves. If noise emission exceeds the legally determined limits. Roll up sleeves towards the inside only. no specific dangers for the operator are to be expected. For this reason. etc. • Always ensure sufficient ventilation and aeration. professional association) carry out a measurement. grease or oil) immediately after spilling due to risk of slipping! • At the work place. safety goggles. • Clean off any spilled liquids (cooling lubricant. Take off wrist watches. the MAC limit value of the total concentration of oil vapour and oil aerosol of 10 mg/m3 must be observed! Therefore always ensure sufficient ventilation and aeration! If necessary.General safety regulations General This machine has been built according to the state-of-the-art technology and to the current safety regulations. If the limit is exceeded. for the sake of your own safety. you must monitor the noise emission directly on-site during machining. ! Warning When operating the machine.. wear the necessary personal safety equipment including safety boots. inform your supervisor. please heed the following instructions: • When working with the machine. It is assumed that the operating personnel is adequately trained in the operation of machine tools. have the relevant controlling authority (e. wrong handling can result in serious injuries that may become fatal. change process conditions and/or have an extractor installed! • After switching off the machine by means of the main switch the socket at the switch cabinet is still alive! 10 . Provided that it is operated properly.g. wear hearing protection! • To keep the noise level of the machine to a minimum. rings. chains and similar jewellery before starting work! • If the noise level is high. as well as close fitting work clothes and hair protection for long hair. Hermle AG will not be liable for any damage which may occur as a result thereof! • Operate the machine only when it is in flawless and reliable condition.g.these changes must be agreed upon with Hermle AG! In the absence of such agreement. Employer's Liability Insurance Association)! If these regulations are not displayed at your work place. Eliminate any defects that occur immediately! • All safety and warning signs on the machine must be complete and fully legible at all times! • The operator must provide appropriate instructions and monitoring to ensure that the work area around the machine and the area around it are clean and tidy! • Read the accident prevention regulations of your controlling authority (e.this applies especially to later additions of foreign additional units. please inform the person in your company responsible for safety! 11 . modifications of the control concepts or even modifications of protective devices .General safety regulations • If the owner of the machine performs modifications on the machine . please heed the following instructions: • As long as the machine is working. For this reason.General safety regulations Operational safety ! Warning When operating the machine.) are securely tightened! • Do not reach between milling spindle and work piece. equipment or tools! • The protective cabin must always be closed completely during operation and may not be opened! • Use only tools which are suitable for machining the respective material. which are used to load the machine. etc. • Ensure correct and safe clamping of the work pieces. must be adequate for the purpose and provide sufficient lifting capacity! • It is recommended to install an extraction system when machining graphite or materials the machining of which produces fine dust! • Each time before setup. • The work piece has to be securely mounted and/or clamped with adequate clamping devices! 12 . • The use of grinding wheels and cutting-off wheels is not allowed! • When working in an area with rotating tools. do not wear protective gloves – risk of the hand being caught in the rotating tool! • Work pieces and mounting devices may only be handled using appropriate loading devices! • Lifting tackles and loading devices. Please also note that some tools are only allowed for certain rpm ranges and are subject to wear. do not reach into the area of rotating shafts. remove the tool from the spindle and make certain that all fastening screws (for example clamping devices. wrong handling can result in serious injuries that may become fatal. nuts or similar parts must protrude from the clamped tool.General safety regulations • No screws. • You must wear safety goggles when working with the cabin open! • The use of cooling lubricants containing more than 15% by volume of inflammable liquid (e. large-sized tools or special tools could thus erroneously be operated up to the possible maximum spindle speed. • When changing tools.g. refer inter alia to the technical documents of the ancillary equipment which are enclosed in the "Machine documentation" folder! 13 . explosive materials (e. • Change tools on time before they become blunt and are then at risk to fracture. magnesium) is not allowed! • The machine operator has to ensure that clamping devices and work pieces are clamped correctly! • A manless test run of a new program is strictly prohibited! • To avoid any evaporation during machining.g. oil) is not admissible! • For the operation. Special care must be taken when using far jutting out boring heads or similar objects! • Always wear adequate protective clothing and safety goggles during the setup mode! • The machining of readily flammable. observe the permissible rpm speed! Danger produced by entering the wrong rpm speed (bouncing error during input via keyboard). ensure sufficient cooling lubricant or choose a dry machining method! • Always select milling work in such a manner that no cooling lubricant can splash out of the protective cabin. • Use only safety goggles marked CE (safety goggles according to EN 166 with eye-protecting lenses made of polycarbonate)! Observe the exchange intervals of the eye-protecting lenses. incorrect handling of the equipment and systems can result in serious or fatal injuries. protective devices. 14 . please heed the following instructions: • Before starting work. switched off or in any other way by-passed. repairs)! The machine must not be started without these features! • Safety devices must never be manipulated. may only be removed for servicing work (exchanging parts. make sure that all safety devices of your machine are working properly. The pressure must be checked via the manometer. • It is prohibited to bypass or to manipulate the safety switch of the cabin locks. and that all enclosure parts are present and properly fastened! • Protective cabin. these systems must always be depressurized via the pressure venting valve. For this reason. particularly the locking and switching functions of the door security switches. It is not sufficient to switch off the hydraulic systems . • Before performing any work on hydraulic systems.General safety regulations Equipment and installation safety ! Warning When operating the machine. cover plates etc. repairs). use a special additional shackle). check the floor around the machine for dirt. • The main switch is turned off and unauthorised. • Remove swarf only by means of appropriate devices such as gloves. Every employee working on the machine must incorporate a personal lock in the main switch (if necessary.General safety regulations Safety during repair work Warning ! During servicing work (maintenance.danger from flying swarf and small parts! • When handling coolant lubricants. erroneous starting is not possible (personal lock). swarf hooks! • For inspection and maintenance. • Starting as a result of stored energy is excluded. please heed the following instructions: In general. the following safety instructions apply to repair work: Do not start repair work until: • Movements that represent a danger have come to a standstill. follow the instructions in chapter: "Cooling lubricant unit"! • Regularly wipe off excess grease from the Y spindle and the guideways. refer inter alia to the technical documents of the ancillary equipment which are enclosed in the "Machine documentation" folder! 1 . Repair work may only be carried out with the machine in the de-energized state! Inspection and maintenance • The switch cabinet may only be opened for maintenance reasons by qualified personnel and it is imperative that it stay locked for the rest of the time! • Under no circumstances may the machine be cleaned with compressed air . Before entering the service area. inspection. For this reason. incorrect handling of the equipment and systems can result in serious or fatal injuries. repair work (replacing parts. it is possible that some protective equipment will be removed or disabled. repair work should be carried out with the machine at standstill.g. not enough room. 1 . special organizational and personal measures must be taken. The necessary work may only be carried out by trained persons who are capable of averting possible risks. repair) may only by carried out by who by virtue of their technical knowledge can execute the work competently. carefully and completely and have especially been trained by Hermle AG. ropes.) must be provided for repair work capable of transporting a minimum load of 500 kg (to be able to move the entire machine). • A particular risk potential is encountered in repair work (replacing parts. that is. • When working on devices that are electrically charged. hydraulics. The servicing personnel is at a particularly high risk – for example when: – Working under difficult environmental conditions (e. pneumatics. it is obligatory to have an additional qualified person present that can intervene in case of emergency! • It is absolutely necessary to observe the notes and regulations in the service instructions of Hermle AG! • Lifting tackle (crane.General safety regulations Repair • If at all possible. especially qualified personnel capable of recognizing the risks which may occur and of avoiding accidents and damage must be hired to carry out this work. e. forced posture. repairs).g. unsafe standing position) – Working with the protective devices turned off – Improvising during troubleshooting (unscheduled servicing) – Troubleshooting with the machine running – Unintentional machine movements – Working with different media (e. etc. If this is not possible.g. electricity) • During repair work. In these cases. General safety regulations Environmental safety Caution ! Improper disposal of the machine components (operating materials and assemblies) can cause hazards to people and damage to the environment. observe the state regulations on environmental protection. the disposal of the components (consumables and subassemblies) must be carried in accordance with the regulations of the country in question and in accordance with regional or local provisions. If recycling is not possible. in an environmentally responsible manner! We recommend you to contact a company specialized in waste disposal. the individual components (consumables and subassemblies) of the machine must be passed on to the appropriate recycling process. cooling lubricants. For this reason. 1 . dirty filter elements. • At the end of their service life. please heed the following instructions: • Select oils and cooling lubricants according to their environmental compatibility and look for a supplier who takes care of their proper disposal! • Dispose of waste oil. • In any case. oily swarf etc. 1 . unintended. repair) on gravityloaded axes. dangerous movements due to the force of gravity as the result of a malfunction or incorrect action.General safety regulations Gravity-loaded axes Gravity-loaded axes are axes that can execute unintended. The following gravity-loaded axes are present on the machine: C-Series / B 300: Z slide (spindle slide) A-axis (swivelling rotary table) C-axis (table plate) Lifting axis (pallet changer) ! Danger When carrying out servicing work (maintenance. please heed the following instructions: • Switch off the machine at the main switch and secure the main switch with a padlock against inadvertent switching-on! • Support the axis securely or move/pivot the axis into a safe position. dangerous machine movements can result in serious injuries that may become fatal! For this reason. inspection. • Attaching the axis to a crane is permitted only after receiving approval from a supervisor. Procedure: • Unscrew locking screw [1] on the unlocking switch. the cabin door of the machine can be manually unlocked from the outside by means of an auxiliary unlocking device. • Once the cabin door has been unlocked.General safety regulations C series: Position of the unlocking switch Manual unlocking of the cabin door in case of emergency A B 300: Position of the unlocking switch A In case of emergency. • Turn unlocking screw [2] on the unlocking switch about 1/2 turn toward the right until the cabin door is unlocked. The auxiliary unlocking device is on the top of the cabin door [A]. turn the unlocking screw [2] back into its initial position (recess pointing upwards – see graphic below) and tighten the locking screw [1] again. Unlocking switch: 1 2 19 . General safety regulations 20 . Chapter General technical data 21 . General technical data Feed drive Standard Feed force Rapid traverse Acceleration Diameter and pitch of the feed spindles: X-axis Y axis (C 30) Y axis (C 40) Z axis 7000 N 45 m/min 6 m/s2 40 / 15 mm 50 / 25 mm 50 / 40 mm 40 / 25 mm Dynamic Feed force Rapid traverse Acceleration Diameter and pitch of the feed spindles: X-axis Y-axis Z axis 8500 N 60 m/min 10 m/s2 40 / 20 mm 50 / 40 mm 40 / 30 mm Traverse range C 30 X-axis Y-axis Z-axis 650 mm 600 mm 500 mm C 40 X-axis Y-axis Z-axis 850 mm 700 mm 500 mm Positioning accuracy Positional tolerance Tp in X-Y-Z axes according to VDI/DGQ 3441 0. 22 .1 °C (68 °F).008 mm In order to be able to maintain the positioning accuracy over the entire duration of use. the ambient temperature should be continuously 20 °C +/. using practical experience in applying the latest sound minimizing technology.1 µ Machine lighting 2 halogen lamps > 500 lux Lighting Machine-specific noise emission parameters according to EN ISO 3746 Operation under load (machining) Corrected*) average acoustic pressure level of measuring area Uncertainty Sound power level Uncertainty LpA = 78 dB (A) KpA = 4 dB (A) LWA = 98 dB (A) KWA = 4 dB (A) Noise level *) A correction for external noise and the environment / room is included In order to estimate the noise pollution at the work place (acoustic emissions) derived from the acoustic emission specifications of the machine. it is necessary to consider the sound wave reflections. the proprietor is obligated to arrange the working areas in such a way as to minimize the propagation of sound waves. the actual operating conditions at hand and the influence of the noise emissions of surrounding machines.General technical data Direct measurement X/Y/Z Resolution Input sensitivity Display step Measuring system 0. 23 .1 µ 0.1 µ 0. According to BGV B3 § 5 – valid for working areas: If risk of damage to hearing resulting from noise exists or is anticipated for the insured. In any event. the machine operator must take into consideration the Accident Prevention Regulations for noise (BGV B3). Fault current protective devices When connecting the machine to the mains with an earth-leakage circuit-breaker. If the network structure differs from the previously described TN-S and TN-C. The choice of the cross section of the line to be used for connection to the mains should be made according to the connection conditions laid down in the electrical circuit diagram.50 MVA C 40 2. If the mains voltage differs an autotransformer can be connected in series. the direction of the rotating field must be tested with a measuring device. L1 and L2). Before switching on the machine. The direction of the rotating field must be clockwise. make sure to use selective universal-current sensitive circuit-breakers according to the requirements DIN EN 50178. The electrical circuit diagram is to be found in the compartment on the inside of the switch cabinet.General technical data Electrical connection Connection conditions The machine is equipped with a frequency-controlled converter system. an isolation transformer with a secondary side star point must be provided or requested. System short-circuit capacity The converters are set to sinusoidal current operation. The minimum system shortcircuit capacity (SK network) at the connecting point of the machine must comply with the following data: C 30 with control unit iTNC 530 2.g. For instance an earth-leakage circuit-breaker from Siemens with 63 A and the designation: – 5SZ6468-0KG00 (without auxiliary switch) – 5SZ6468-0KG30 (with auxiliary switch) 24 . This system may be connected only to earthed networks TN-S and TN-C (VDE 0100 part 300) with a nominal voltage of 3 AC 400 V.15 MVA C 30 with control unit S 840 D 2. If necessary. alter the direction of rotation by interchanging 2 phases (e.50 MVA Important An insufficient system short-circuit capacity can result in converter failures as well as in failures and damages of other devices which are connected at the same mains connecting point as the converter. 6 KVA Electrical system internal coolant supply Total connected load of the internal coolant supply Total connected load Important The internal coolant supply must be connected to the same 400 V power supply as the machine but with separate fuses to avoid a possible power failure to the internal coolant supply while the machine is running.g.10 % / 3 PH / 50 Hz 24 V DC 63 A 16 mm2 max. 29 KVA The total connected loads stated refer to a machine equipped with all possible options (e. 41 KVA max. 16. accordingly the loads given are maximum values. 2 . pallet changer). 43 KVA max.General technical data Machine connection data Mains connection (ICS) Control voltage Fuses Line diameter Total connected load of the machine For C 30 U / C 40 U with standard feed drive: Total connected load For C 30 U / C 40 U with dynamic feed drive: Total connected load For C 30 V / C 40 V with standard feed drive: Total connected load For C 30 V / C 40 V with dynamic feed drive: Total connected load Electrics machine 400 V +/. Connection data for internal coolant supply Mains connection (ICS) Control voltage fuses Line diameter 400 V +/. swarf conveyor. additional magazine. 27 KVA max.10 % / 3 PH / 50 Hz 24 V DC 50 A 10 mm2 max. g. 90% at 20 °C) 2 .General technical data Operating conditions for electrical equipment Operating conditions for electrical equipment (according to EN 0204-0) Room temperature Minimum ambient temperature + 5 °C Maximum ambient temperature + 40 C Relative humidity Maximum relative humidity at maximum ambient temperature*) 50% *) higher relative humidities may be allowed at lower temperatures (e. 0 bar Compressed air supply line When connecting your in-house supply to the machine. Compressed air grade (according to ISO 3-1) The quality of the compressed air provided must meet the following conditions: • Residual dust (class 4) Class 4 Maximum number of particles / m3 (particle size "d" (µm)) 0. make sure that the connection is effected by means of a flexible pneumatic hose (internal diameter 11 mm and external diameter 16 mm) and a quick-acting gate coupling (nominal width 7).01 mg / m3 < 6 g / m3 If the machine is. however. the service lives of the machine filters cannot be guaranteed. additionally equipped with sealing air for glass scales (option) in order to obtain extremely high precision.5 < d < / = 1 1000 1<d</=5 10 • Residual moisture (class 4) Class 4 • Residual oil (class 4) Class 4 • Pressure dew point (class 4) Class 4 < / = 3 °C (5.4 F) < / = 0.5 100000 0. Important If the grade of the supplied compressed air does not meet the conditions listed above.1 < d < / = 0. This may result in a malfunction of the measurement system (glass scales)! 2 . it must be guaranteed that there are no large differences in temperature between the supplied sealing air and the ambient temperature of the installation site.General technical data Compressed air connection Connection pressure Pneumatic system p >/= 6. 80 slpm Minimum quantity lubrication (TKM). Optional consumption values Sealing air for spindle + 25 slpm Sealing air for glass scales + 20 slpm Sealing air for tool measurement + 10 slpm Sealing air for C-axis + 35 slpm Sealing air for A-axis + 90 slpm External blast air + 660 slpm Blast air for spindle centre +600 slpm Spindle 28000 rpm 255 slpm Spindle 40 000 rpm + 255 slpm Minimum quantity lubrication (Unilube). 5 tool transports / min) + 30 slpm ZM 87 (max. internal + max. 2 pallet changes / min) + 220 slpm Pallet changer PW 800 (max. external + max. 2 pallet changes / min) + 330 slpm ZM 43 (max.General technical data Basic consumption value Standard machine 120 slpm The consumption of compressed air is calculated on the basis of 3 tool changes per minute. 200 slpm Pallet changer PW 160 (max. 6 tool transports / min) + 24 slpm ZM 157 (no information necessary due to minimal consumption) Calculation of the individual consumption values V1 B = (120 slpm + "X" slpm) x 1013 mbar x 293 K 273 K x 6000 mbar = "X" litres/min (at 6 bar operating pressure) "X" slpm = Sum of optional consumption values 2 . This means that proof can be provided as to which cooling lubricants have been in use with which machine types and for how long. Depending on the corresponding application.General technical data Selection of cooling lubricant Cooling lubricant Note Hermle AG cannot be held liable for any damage to the machine caused by inappropriate cooling lubricant or insufficient. On the basis of their extensive volume of data. the owner of the machine should select the cooling lubricant most suited to his machining process with his cooling lubricant supplier. well known cooling lubricant manufacturers can supply. Hermle AG cannot recommend any special kind of cooling lubricant. in most cases without problems a certificate of use. incorrect maintenance of the cooling lubricant by the owner of the machine. 29 . Due to the fact that the wide range of machining processes may also lead to different cooling lubricants being used. General technical data The basic requirements listed below should, however, always be considered when choosing a cooling lubricant: • Suitable for the planned machining processes and usable for the widest possible range of applications. • Suitable for the material being processed. • Suitable for both roughing and finishing. • Readily miscible with water (emulsions). • Offering protection against corrosion at appropriate concentrations. • Good metal removing capacity and little foaming. • Environmentally friendly - disposal by the supplier. • The cooling lubricant cannot be mixed with oil from leaks. Leak oil, which under certain circumstances may get into the cooling lubricant, must not be absorbed by the latter but it should float on its surface. • The cooling lubricant emulsion may not contain more than 15 vol. % of flammable liquid (e.g. oil). • The cooling lubricant concentrate must not be affected by bacteria or by fungi and, if made up according to the instructions, not irritate the skin. Request appraisals of skin compatibility. • Cooling lubricants must be designed so that no seals, elastomers, machine paint or machine parts are affected by them. This is usually guaranteed in the case of cooling lubricants containing mineral oil. In the case of mineral-oil-free or semi-synthetic cooling lubricants, for example ester-based products, this must be proven in each individual case. If ester-based cooling lubricants are used, it is essential to consult the respective cooling lubricant manufacturer. • The cooling lubricant must be well filterable and separable. • To prevent various chemical reactions on the machine, the cooling lubricant emulsion should be obtained from the same manufacturer as the operating lubricants used in the machine. Filling amount Filling amount without internal coolant supply C 30 C 40 Filling amount with internal coolant supply C 30 C 40 240 litres 350 litres 1190 litres 1300 litres 30 General technical data 3 axes Designation of the machine axes Z+ Y+ X+ 4 / axes Z+ C+ Y+ A+ X+ 31 General technical data Data transfer There are connecting sockets on the right-hand side of the switch cabinet for the data input and output. • Socket V 24 - RS 232-C (only for machines with Heidenhain Control) • Ethernet 10/100 Base T (to 100 MBits/s; depending on the network load), RJ 45 connection possibility The configuration of the pins of both interfaces is given in the circuit diagram of the machine. Data backup To guard against a certain data loss, a CD is enclosed in the side pocket of the switch cabinet when the machine is delivered. This CD contains a backup of various machine data of operational significance. Be sure to make a backup copy and keep it in a safe place! 32 Chapter Transport and installation 33 . • To continue. and the required loading width / loading height / loading length (e. the forwarding company or transporter must observe the following cautions: • Special caution and care must be employed at all times to exclude dangers for persons! • The means of transport must meet the requirements of the highway code and licensing regulations! • The dimensions and permissible total weight / carrying capacity of the transport vehicle must be approved for the machine in question (including packaging and transport device)! This means for example observing the permissible total weight of the transport vehicle. 34 . a so-called "Curtainsider. the load must be protected (e.i. Edscha or Hamburg covering" (no throw-over tarps that rest on the machine)! To prevent friction-related damage caused by the tarp.g.Transport and installation General transport regulations ! Danger A sliding load during transport with a transport vehicle (including in road traffic) can result in serious or even fatal injuries to the transport personnel and any persons that may be present.e. use flatbed trailer)! • The transport vehicle / transport surfaces must be air-cushioned! • The transport vehicle must be equipped with an extendable tarp and frame .6) must be used. • Tested anti-slip mats (coefficient of friction at least µ = 0. the capacity of the loading surface for receiving loads. pallet changer and accessories.g. by bubble wrap). For the machine with additional magazine. • The anchor points and lashing equipment must be in perfect condition from a safety perspective. Because of this. at least 16 belts are required in total. at least 4 belts are required. see the following page. • Anchor points must be present on the transport vehicle according to DIN EN 12640 with a rating of at least 20 kN (2000 daN) of load! • Tension belts / lashing chains in flawless condition according to DIN EN 12195-2 (for tension belts) or DIN EN 12195-3 (for lashing chains) must be provided with a load capacity of at least 2000 daN! The number of tension belts depends on the number of items to be loaded. For the machine alone. g. ship. no nails. grease.Transport and installation • The transport surface must be clean. as all of the transport information listed in this section only applies for transport using a transport vehicle (truck). or other residue)! • Rubber mats must be placed at points where the clamping devices rest on machine components or transport devices for protection between the clamping device or transport device and the machine component. or air can result in serious or even fatal injuries to the transport personnel and any persons that may be present. free of grease and ice (e. to prevent damage to the clamping device and the machine. Because of this. ! Danger A sliding load during transport by rail. sand. make certain the machine is properly secured for the transport vehicle being used! The clamping and screen forces must be calculated by a specialist company for the specific transport type and the machine protection designed accordingly. oil. 3 . • Only use means of transport (fork lift trucks. and commissioning of the machine only by the Hermle AG Customer Service or a service authorized by Hermle AG. when installing the machine.Transport and installation General safety instructions ! Danger When transporting and installing the machine. steadily. straps) on the transport pallet! • Lift and put down the machine only vertically. an open door must always be taken into consideration! This is why a minimum clear passageway of 500 mm around the entire machine must be maintained and increased by the door width in the door area! 3 . blocked escape and rescue routes can result in danger to life.) with sufficient lifting power.e. For this reason. machine components. make absolutely sure that their maximum load capacity is sufficient to lift the transport weight of the machine! The maximum load capacity of a lifting tackle is usually clearly marked. heavy load rollers etc.).g. For this reason. suspended loads or wrong handling can result in serious injuries or death. cranes. i. • Affix your lifting tackles only to the HERMLE lifting devices provided for this purpose! • Before unloading the machine. and without jerky movements! • Keep unauthorized persons outside of the danger area during machine installation and commissioning! ! Warning In case of fire. make sure that there are no loose part (e. please heed the following instructions: • People must never be allowed to stand under heavy loads! • The installation of the machine may only be performed by sufficiently qualified personnel. chains. lifting trucks. ropes etc. more than the indicated transport weight! • When selecting the lifting tackle (straps. please note that if there is an escape route to both sides. The maximum load capacity of a lifting tackle is usually clearly marked. • When selecting the lifting tackle (straps. i. note the centre of gravity and align your means of transport and lifting tackle accordingly! The centre of gravity is indicated on the packing case by a suitable symbol. crane cross-beams.e.) only to the lifting points provided for this purpose and in the required angular position! The lifting points are indicated along with the required angular position of the lifting tackle on the packing case by suitable symbols.Transport and installation Information on the transport in a packing case ! Danger When transporting the machine in a packing case. • Make sure that the weight is evenly distributed to all lifting tackles! • Use a crane cross-beam suited to this purpose! • During transport by fork lift truck. keep unauthorized persons out of the danger area! • The symbols (according to ISO R/780) written on the packing case must be observed as handling instructions! • Only use fork lift trucks and other lifting trucks with sufficient lifting power. please heed the following instructions: • People must never be allowed to stand under heavy loads! • During machine transport. etc. ropes chains. • Attach the lifting tackle (straps. chains. only drive into the openings provided for this purpose at the case bottom! Guide the forks far enough into the openings so there is no possibility the packing case could fall over! Watch out for centre of gravity of the packing case! 3 . make absolutely certain that their maximum load capacity is sufficient to lift the transport weight (gross weight) of the packing case. etc. suspended loads or wrong handling can result in serious injuries or death. For this reason.). ropes. capable of carrying more than the transport weight indicated on the packing case (gross weight)! • Before lifting the packing case. note the weight and dimensions of the packing case! You will be informed of the weight and dimension prior to the delivery of the machine. Should any damage be detected. please notify the HERMLE AG Service Department at once! • After removing the packing case. • Be sure not to damage the machine during unpacking! Unpack the machine and its components carefully.Transport and installation • Lift and put down packing case only vertically. evenly and without jerky movements! • Only qualified shipping companies are permitted to transport the machine in a packing case. check whether the delivered goods are complete and inspect them for possible damage during transport. please observe the information of these transport instructions! 3 . Important • When selecting a means of shipping equipment and lifting tackles. Transport and installation Definition of the symbols used on the packing case Fragile goods The packing case must be handled with care and under no circumstances toppled or tied with strings! Top The packing case must always be transported, handled and stored in such a way that the arrows always point upwards. Excessive tilting or turning over is prohibited! Attach here This symbol indicates to which point and in which angular position of the packing case the lifting tackle (straps, ropes, chains, etc.) must be attached. If the packing case does not hang horizontally, the lifting tackle must be adjusted accordingly on one side! Protect from moisture The packing case must be protected from excessively high humidity at any time. This means that it must be stored in closed rooms! Centre of gravity This symbol indicates the position of the centre of gravity, which must be observed under all circumstance when lifting it by crane or fork lift truck! Do not place the forks here This symbol is only attached to the sides of the packing case which may not be lifted using the fork lift truck. If this symbol is missing, lifting is allowed. 39 Transport and installation C 30 Transport weight Transport weight of the standard machine without accessory equipment: C 30 approx. 9200 kg C 30 Transport dimensions Transport dimensions of the standard machine without accessory equipment: 240 (with detached Z motor and energy chain) 2214 314 40 243 (with dismounted Z motor) 292 (with standard transport / deliver condition) Transport and installation Important When transporting the machine, make certain to note where the centre of gravity is and to arrange the transporting equipment and lifting tackles accordingly! The transport centre of gravity is identified on the machine / shipping package by the following symbol. C 30 Transport centre of gravity Rear view 120 10 34 Side view 120 4 41 Transport and installation C 40 Transport weight Transport weight of the standard machine without accessory equipment: C 40 approx. 10300 kg C 40 Transport dimensions Transport dimensions of the standard machine without accessory equipment: 240 (with detached Z motor and energy chain) 234 314 42 243 (with dismounted Z motor) 292 (with standard transport / deliver condition) . Transport and installation Important When transporting the machine. C 40 Transport centre of gravity Rear view 1139 10 29 Side view 1139 9 43 . make certain to note where the centre of gravity is and to arrange the transporting equipment and lifting tackles accordingly! The transport centre of gravity is identified on the machine / shipping package by the following symbol. 44 . For this reason.Transport and installation Anchor points for securing the load 1 1 2 2 ! Danger A sliding load during transport (including in road traffic) can result in serious or even fatal injuries to the transport personnel and any persons that may be present. please make sure that the machine is secured correctly! The available anchor points for securing the machine when loading are 2 lifting eyes in the interior of the machine [1] at the front of the machine and 2 lifting eyes on the machine bed [2] at the rear of the machine. heavy load rollers. but these devices can also be borrowed from Hermle AG for a fee. e. • A suitable crane is always needed to lift the machine from the transport pallet! More detailed information can be found in the section "Transport by crane". • The switch cabinet of the machine is screwed down to the machine during transportation and must be detached prior to being put into operation. • Please return the transport aids (transport device.g. scales or lines are stepped on. • The forwarding company has to provide the crane cross-beam. etc.Transport and installation Transport information Caution ! When removing the transport device. 4 . Stepping on these sensitive machine components should therefore be avoided.) after the machine has been commissioned. guides. damage can be caused to the machine if sensitive machine components. 4 .Transport and installation Storage information • The machine is delivered in a preserved state and can be stored at a closed. Important Humid storage rooms of more than 65% of relative humidity and a variable ambient temperature are unsuitable. a suitable long-term preservation is required (HERMLE AG must be consulted about this). its properties will remain unchanged. If the intended time of storage is longer. for example. These changes may be caused. its properties will be adversely affected. by extreme variations in temperature or humidity. Make sure that no condensation takes place. Under unfavorable storage conditions and if the machine is stored incorrectly. dry location for up to 6 months. • If the machine is stored correctly. As you do this. please contact the Hermle company! 4 . with a standard transport. sufficient free space to move around in and adequate room for the machine operator. – Eliminate or identify areas with risk of tripping or other dangers! • Check the transport route to the machine location Determine a transport route to the location where the machine will be installed. are too large for your facilities. The machine dimensions can be found in the chapter entitled "Machine dimensions and weight"! – Please note that in the direction of escape you must always factor in an open door on both sides! This is why a minimum clear passageway of 500 mm around the entire machine must be maintained and increased by the door width in the door area! – Make certain in addition there is good accessibility to operate and maintain the machine. in addition to long-term machining precision. please make the following preparations related to the machine location: • Determine the machine location and space required Determine a location for the machine. In doing so note among other things: – Door openings – Overhead clearances – Areas to move off to the side – Other obstructions (for example building supports) – The nature of the surface (in terms of transport on heavy load rollers) – Ascending and descending routes – Carrying capacity and size of elevators If the transport dimensions of the machine.Transport and installation Preparations related to the machine location Note To ensure problem-free and safe installation of the machine. note the following: – Take into consideration the dimensions of the machine. – To achieve optimal protection against slipping.Transport and installation • Check the quality of the machine location Please note that the quality of the machine location has a significant effect on the machining precision of the machine. The following requirements must therefore urgently be observed: – Make certain the weight and weighted forces of the machine are safely contained by the bearing constructions and have a structural engineer provide proof of sufficient carrying capacity. Instead place it close to where there is a support. do not place the machine near the middle of beams (where the deflection of the beam is greatest). grease. thickness > 200 mm Concrete base plate on a natural soil base (subsurface sufficiently compacted) – Every precision pad for the machining centre can correct 0. – If at all possible. Consistently high machining precision can only be achieved by observing the following requirements: – Set the machine up on a concrete base plate Minimum quality: B 25 reinforced. – Provide adequate lighting conditions in the area of the machine's location. – Avoid surface vibrations caused by nearby machines and/or fork lift truck traffic that affect the machine location. make certain the installation surface in general and in particular the support surfaces for the precision pads are free of dirt.5 mm of unevenness in the floor at its supporting surface. 4 . Always clean them with a solvent such as acetone. and oil. This could cause a breakthrough in the ceiling or bearing construction and could also have a negative effect on machining precision. – Make certain there is a constant power supply with a maximum permissible deviation of +10% / -10%. When installing the machine on top of the ceiling or bearing construction. a certain amount of yield and bend must be assumed for the floor beams. greases and cooling lubricants used by the machine are water pollutants. the machine must be installed in an adequate waterproof collecting pan. especially in water protection areas and areas close to streams. Therefore. In this event. Planning and installation must be done with special care. into the ground or into the sewer system. Because of this. – The collecting pan must not have a negative effect on the evenness of the installation surface. reinforced 49 . please observe the following requirement: – The base of the machine location must be sealed and resistant to all materials used in the machine (oil-proof base without expansion joint). – The recess for the machine leg in question must be designed to ensure the adjusting screw of the precision pad is accessible. These polluting substances must not get into water sources. Please note that the collecting pan must meet special requirements related to the machine installation. Machine leg Collecting pan with recess > 200 mm Adjusting screw Precision pad Base plate Concrete B 2. If there is no way to guarantee this condition. environmental protection requirements must be taken into consideration and observed. get in touch with the Hermle AG if required. Please observe the following requirements when designing the collecting pan: – The collecting pan must have a recess in the area of the machine legs so that the precision pads rest directly on the even floor surface and not on the collecting pan.Transport and installation • Check the floor of the machine location to ensure that oil cannot leak through The oils. rivers or lakes. Danger of the machine slipping! – The machine and swarf conveyor must be placed higher to compensate for the dimension of the collecting pan. 1.8 °F) for 72 hours.1 °C (68 °F +/.1. Consistently high machining precision can only be achieved by observing the following requirements: – Maintain a constant ambient temperature of approximately 20 °C +/. heated bodies or draughts of air. Preconditions for commissioning Note Preconditions for an exact geometrical acceptance check during commissioning: • Moment for start of operations The time of commissioning must be selected such that the machine will have stayed at the installation site on its precision pads for 72 hours before the geometrical acceptance check (last step of commissioning) is made! • Ambient temperature The machine must have stayed in a constant ambient temperature of approx.8 °F). – Avoid local heating up and cooling off on the machine. – Keep the relative humidity continuously under 65%. etc. 20 °C +/.Transport and installation • Check the climatic conditions at the machine location Please note that the climatic conditions at the machine location have a significant effect on the machining precision of the machine. for example caused by direct sunlight.1 °C (68 °F +/. – For extremely high precision requirements. before the geometrical acceptance check is carried out! 0 . place the machine in an air-conditioned room. the pullout dimension (see item Machine dimensions in chapter "Machine dimensions and weight") of the swarf drawer or the swarf conveyor. observe the instructions in the following chapter "Electrical connection" and the instructions in the chapter "General technical data". • Cooling lubricant Have a suitable cooling lubricant available. please make the following preparations: • Floor evenness at machine location Measure the evenness of the floor in the area where the machine will be installed according to the "Dimension sheet on floor evenness at the machine location". • Positioning Place the machine on the precision pads at its intended installation site and observe the instructions in the following chapter "Arrangement of the precision pads" and in the subsequent transport chapters. • Maintenance and service area Please ensure that the machine is easily accessible from all sides for maintenance and service work. • Electrical connection Prepare an electrical connection for the machine and a separate electrical connection for the internal coolant supply (optional). When making the electrical connection from the machine to your in-house connection. the Hermle Service Department will assume optimum floor evenness during the commissioning of the machine. 1 .Transport and installation Preparations for commissioning Note To ensure problem-free and reliable machine commissioning by Hermle Customer Service. Hermle AG reserves the right to invoice additional costs that may be incurred due to missing information related to the floor evenness. observe the instructions in the following chapter "Pneumatic connection" and the instructions in the chapter "General technical data". Note the instructions in the chapter "General technical data". Observe. depending on the equipment of the machine. • Pneumatic connection Prepare a pneumatic connection for the machine and make the connection. Should the completed dimension sheet of the Hermle AG not be available when the machine is delivered. Make these connections. When making the pneumatic connection from the machine to your in-house connection. Please fill in the dimension sheet and send it back to Hermle AG prior to the planned delivery of the machine. make sure to use selective universal-current sensitive circuit-breakers according to the requirements DIN EN 50178. If the mains voltage differs an autotransformer can be connected in series. The direction of the rotating field must be clockwise. The minimum system shortcircuit capacity (SK network) at the connecting point of the machine must comply with the following data: C 30 with control unit iTNC 530 2.g. For instance an earth-leakage circuit-breaker from Siemens with 63 A and the designation: – 5SZ6468-0KG00 (without auxiliary switch) – 5SZ6468-0KG30 (with auxiliary switch) 2 .50 MVA Important An insufficient system short-circuit capacity can result in converter failures as well as in failures and damages of other devices which are connected at the same mains connecting point as the converter. If necessary.50 MVA C 40 2. Fault current protective devices When connecting the machine to the mains with an earth-leakage circuit-breaker.15 MVA C 30 with control unit S 840 D 2. an isolation transformer with a secondary side star point must be provided or requested. The choice of the cross section of the line to be used for connection to the mains should be made according to the connection conditions laid down in the electrical circuit diagram. alter the direction of rotation by interchanging 2 phases (e. If the network structure differs from the previously described TN-S and TN-C. The electrical circuit diagram is to be found in the compartment on the inside of the switch cabinet. Before switching on the machine. This system may be connected only to earthed networks TN-S and TN-C (VDE 0100 part 300) with a nominal voltage of 3 AC 400 V.Transport and installation Electrical connection Connection conditions The machine is equipped with a frequency-controlled converter system. System short-circuit capacity The converters are set to sinusoidal current operation. L1 and L2). the direction of the rotating field must be tested with a measuring device. make certain it is properly fastened. please heed the following instructions: • Only skilled electricians may connect the machine to the mains! • You must ensure that the mains supply line is dead when connecting the machine! • The mains supply line must only be led into the switch cabinet through the bore hole on the floor of the switch cabinet designed for that purpose! • In general when laying the mains supply line. Under no circumstances may it come in contact with movable machine parts! • To continue. see the following page! 3 . live machine parts can result in serious injuries or death! For this reason.Transport and installation A Graphic 2 L1 L2 L3 N PE Graphic 1 When connecting the machine proceed as follows: Mains phase Mains phase Mains phase Zero conductor Protective earth conductor (grn/yel) ! Danger When connecting the machine to the mains. and PE. Important If the mains supply line is fed into the machine from above. Connect the designated lines according to the circuit diagram to terminals L1. • Make the mains power connection in the switch cabinet according to graphic 2.Transport and installation • Turn off the power to the mains supply line! • Lay the mains supply line and guide it into the switch cabinet through the bore hole designed for that purpose on the floor of the switch cabinet. Make sure that the connection of the mains supply line is done on the shortest way from the bore to the connection point. Pneumatic connection When connecting your in-house supply to the machine. N. L3. make sure that the connection is effected by means of a flexible pneumatic hose (internal diameter 11 mm and external diameter 16 mm) and a quick-acting gate coupling (nominal width 7). 4 . it should be laid at the corresponding position [A] (see graphic 1). L2. Transport and installation C 30 z Si e 24 0-9 Arrangement of the precision pads 10 14 4 11 0 40 t: 1 fron : 100 k bac C 40 z Si e 24 0-9 10 14 4 19 0 0 t: 1 fron : 100 k bac When positioning the enclosed precision pads observe the graphics given above. Make sure that the precision pads are located in the middle position (74 mm) and the adjusting screw of the two front pads points towards the front side of the machine and the adjusting screw of the rear ones towards the rear of the machine. . Transport and installation Transport by fork lift truck Situation: Right-side transportation (preferably) Situation: Left-side transportation . Transport and installation Transport information Traverse Transport information min. 9 (C 30) 114 (C 40) max. 1 (C 30) 14 (C 40) Fork of the fork lift truck . 100 mm (transport from the right side) min.) having sufficient lifting power. lifting trucks etc. 100 mm (transport from the right side) min. 2100 mm (transport from the left side) • If no fork lift truck meeting the requirements is available on-site. if necessary! .e.Transport and installation Procedure: ! Danger When transporting the machine by fork lift truck. i. more than the indicated transport weight! • When transporting the machine with the fork lift truck. there is a risk of toppling! • Lift and put down the machine only vertically. suspended loads or wrong handling can result in serious injuries or death. keep unauthorized persons out of the danger area! • People must never be allowed to stand under heavy loads! • Make certain the transport routes are safe and take appropriate safety measures. steadily. Otherwise. • Only use means of transport (forklift trucks. please heed the following instructions: • The transport of the machine by fork lift truck may only be performed by sufficiently qualified personnel or by a forwarding company authorized by the Hermle AG. 2000 mm (transport from the left side) – Fork length for C 40: min. contact a forwarding company qualified to transport the machine by means of an appropriate fork lift truck! Other forms of transport except transport by crane or by heavy load rollers are not allowed! • The machine may be transported by fork lift truck only complete with pallet! • When driving the forks into the transport pallet. it is essential to ensure that the forks are inserted through the openings provided for this purpose in the transport pallet as far as the opposite traverse (see graphic). For this reason. observe the required: – Minimum lifting capacity of the forklift truck of 12000 kg – Fork length for C 30: min. and without jerky movements! • During machine transport. depending on the situation. there is a risk of toppling! • Transport the machine only to its installation site. When doing this. Proceed in accordance with the instructions given in the chapter "Transport by crane". • Then position the precision pads under the floor contact areas of the machine. • Please unpack the machine and its components carefully. Should any damage be detected. please notify the Hermle AG Service Department at once. • Unscrew the bolted connections holding the machine to the transport pallet (wrench size 24). If it is not possible to place the machine directly on the corresponding installation site using the fork lift truck. • Detach and/or remove all enclosed machine parts (control panel.) from the transport pallet and screw in completely the levelling feet of the electrical cabinet. 9 . the machine must be transported further with a crane or heavy load rollers. see the following page. Proceed in accordance with the instructions given in the chapter "Transport by crane" and/or the chapter "Transport by heavy load rollers". check whether the delivered goods are complete and inspect them for possible damage during transport. • Lift the machine vertically by crane as far as necessary and remove the pallet. • To continue.Transport and installation • Drive the forks of the fork lift truck from the right side (exceptionally also from the left) into the recesses of the transport pallet provided for this purpose and lift the whole machine carefully. etc. Proceed in accordance with the instructions given in the chapter "Arrangement of the precision pads". Otherwise. make sure that the operating panel be not damaged. When driving in ensure that the forks reach as far as the opposite traverse (see graphic). 0 . from the top. through the hole in the floor contact area into the threaded bore of the precision pad. lower the machine completely onto the precision pad. Make sure that you turn the threaded rods on the front of the machine into the outer threaded bores of the precision pads and on the rear of the machine into the inner threaded bores of the precision pads! • If it is necessary to compensate for deviations as set out in the "Dimension sheet for floor evenness at the machine location". • Following this. • Repeat this procedure for every further precision pad until the machine then stands entirely on the precision pads. slide the required support plate (s) between the precision pad and the machine leg prior to lowering the machine. • Finally.Transport and installation • Lower the machine carefully and almost entirely onto the first precision pad (it should still be possible to shift the precision pad under the floor contact area). turn the threaded rod by hand. 1 . By turning the adjusting screw on the side of the precision pads.Transport and installation Important Under no circumstances should the precision pads be screwed down completely onto the floor contact areas of the machine! If the precision pads are screwed completely down to the floor contact areas. you can obtain a horizontal alignment of the machine. keep them for a possible later transport – otherwise send them back to Hermle AG). • Remove the lifting device (four lifting eyes and cross-beam) in the inside of the machine (if necessary. • During the commissioning of the machine. the Hermle Service Department takes care of screwing down the precision pads completely onto the floor contact areas and performing an exact alignment of the machine. • Place a level on the machine table afterward to make a horizontal check. this can lead to damage to the precision pads when the machine is aligned. Always make certain the machine is suspended horizontally on the crane! 1 100 – 100 1039 2 . the ropes can also be extended by means of shackles.Transport and installation Transport by crane C 30 – Transport with traverse beam 1324 Lifting eyes (Lifting device) 1344 Note To reach the correct rope dimension or to align the machine horizontally. Always make certain the machine is suspended horizontally on the crane! 1 100 – 100 1039 3 .Transport and installation C 30 – Transport with H-frame 22 02 32 12 Lifting eyes (Lifting device) Note To reach the correct rope dimension or to align the machine horizontally. the ropes can also be extended by means of shackles. Always make certain the machine is suspended horizontally on the crane! 2 100 – 100 9 4 . the ropes can also be extended by means of shackles.Transport and installation C 40 – Transport with traverse beam 144 Lifting eyes (Lifting device) 144 Note To reach the correct rope dimension or to align the machine horizontally. Always make certain the machine is suspended horizontally on the crane! 2 100 – 100 9 .Transport and installation C 40 – Transport with H-frame Lifting eyes (Lifting device) Note To reach the correct rope dimension or to align the machine horizontally. the ropes can also be extended by means of shackles. lifting frames. suspended loads or wrong handling can result in serious injuries or death. steadily. etc. use only a suitable traverse beam or H-frame.) with sufficient lifting power. contact a forwarding company qualified to transport the machine by means of an appropriate crane! Other forms of transport are not allowed except transporting by fork lift truck or by heavy load rollers! • Affix your lifting tackles only to the HERMLE lifting devices provided for this purpose (see graphic)! • Make sure that the weight is evenly distributed to all lifting tackles! • Lift and put down the machine only suspended horizontally. For this reason. i.e. please heed the following instructions: • The transport of the machine by crane may only be performed by sufficiently qualified personnel or by a forwarding company authorized by the Hermle AG. ropes. and without jerky movements! • During machine transport. • Ropes or chains of equal length must be used to suspend the machine from the crane beam (100 mm – 100 mm)! • When transporting the machine with the crane.Transport and installation Procedure: ! Danger When transporting the machine by crane. more than the indicated transport weight! • To transport the machine by crane. • Only use means of transport and lifting equipment (cranes. observe the required: – Minimum lifting force of the crane of 12000 kg – Minimum load capacity of the crane cross-beam: 12000 kg – Individual load capacity for each rope / chain of at least 5000 kg • If no crane meeting the requirements is available on-site. if necessary! . keep unauthorized persons out of the danger area! • People must never be allowed to stand under heavy loads! • Make certain the transport routes are safe and take appropriate safety measures. please notify the Hermle AG Service Department at once. Proceed in accordance with the instructions given in the chapter "Transport by fork lift truck" and/or the chapter "Transport by heavy load rollers". • Please unpack the machine and its components carefully. check whether the delivered goods are complete and inspect them for possible damage during transport.) from the transport pallet and screw in completely the levelling feet of the electrical cabinet. • Unscrew the bolted connections holding the machine to the transport pallet (wrench size 24). Should any damage be detected. make sure that the operating panel be not damaged. • Then position the precision pads under the floor contact areas of the machine. • Tighten the transport ropes carefully. etc. Proceed in accordance with the instructions given in the chapter "Arrangement of the precision pads". the machine must be transported further by means of the fork lift truck or the heavy load rollers. depending on the situation. When doing this. • To continue. • Lift the machine vertically by crane as far as necessary and remove the pallet. If it is not possible to place the machine directly on the corresponding installation site using the crane.Transport and installation • Hang the transport ropes of the crane cross-beam into the lifting eyes on the body of the machine. see the following page. making sure that the four transport ropes are free and will not damage any part of the machine upon lifting. • Detach and/or remove all enclosed machine parts (control panel. • Now lift the machine vertically by crane and transport the machine to the intended installation site. . . this can lead to damage to the precision pads when the machine is aligned.Transport and installation • Lower the machine carefully and almost entirely onto the first precision pad (it should still be possible to shift the precision pad under the floor contact area). • Finally. • Remove the lifting device (four lifting eyes and cross-beam) in the inside of the machine (if necessary. Make sure that you turn the threaded rods on the front of the machine into the outer threaded bores of the precision pads and on the rear of the machine into the inner threaded bores of the precision pads! • If it is necessary to compensate for deviations as set out in the "Dimension sheet for floor evenness at the machine location". slide the required support plate (s) between the precision pad and the machine leg prior to lowering the machine. from the top. turn the threaded rod by hand. lower the machine completely onto the precision pad. Important Under no circumstances should the precision pads be screwed down completely onto the floor contact areas of the machine! If the precision pads are screwed completely down to the floor contact areas. • Following this. the Hermle Service Department takes care of screwing down the precision pads completely onto the floor contact areas and performing an exact alignment of the machine. • Repeat this procedure for every further precision pad until the machine then stands entirely on the precision pads. keep them for a possible later transport – otherwise send them back to Hermle AG). • Place a level on the machine table afterward to make a horizontal check. you can obtain a horizontal alignment of the machine. By turning the adjusting screw on the side of the precision pads. • During the commissioning of the machine. through the hole in the floor contact area into the threaded bore of the precision pad. Transport and installation Required auxiliary equipment 3 heavy load rollers (2 rigid. if necessary Minimum load capacity 8000 kg Figure 3 9 . 1 steerable) Minimum load capacity 6000 kg 4 rubber supports (position them accordingly) Transport by heavy load rollers Figure 1 1 hardwood support (appropriate size) 1 lifting pad (preferably!) Minimum load capacity 8000 kg Figure 2 Hydraulic jack. 3.Transport and installation Machine from the floor onto the heavy load rollers Order of the lifting points for the lifting pad/hydraulic jack Heavy load rollers. 2. 2. Machine base unit Steel plate Hardwood supports 3. 0 . rigid Switch cabinet 1. Graphic 1 Heavy load roller. steerable 1. steerable Graphic 2 1. 2. 1 . 2. rigid Switch cabinet 3. Heavy load roller. 3.Transport and installation Order of the lifting points for the lifting pad/hydraulic jack Machine from the heavy load rollers onto the precision pads Heavy load rollers. Machine base unit Steel plate Hardwood supports 1. Transport and installation Representation of the same lifting points but with hydraulic jack Attachment point front left Attachment point laterally right Attachment point rear left (inside) 2 . wrong handling can result in serious injuries or death. hydraulic jack etc. It is imperative to observe the safety instructions and procedures in the chapters "Transport by fork lift truck" and/or "Transport by crane"! • The transport of the machine by heavy load rollers may only be performed by sufficiently qualified personnel or by a forwarding company authorized by the Hermle AG. contact a forwarding company qualified to transport the machine by means of appropriate heavy load rollers. please heed the following instructions: • Before you put the machine on the heavy load rollers. observe the required: – Individual load capacity for each heavy load roller of 6000 kg – Minimum lifting power of the hydraulic jack or lifting pad of 000 kg • If no heavy load rollers meeting the requirements are available on-site. more than the indicated transport weight! • When transporting the machine with heavy load rollers.) having sufficient lifting power. the heavy load rollers must be secured to prevent them from rolling away unintentionally! 3 . i. keep unauthorized persons out of the danger area! • People must never be allowed to stand under heavy loads! • Make certain the transport routes are safe and take appropriate and necessary safety measures! • When the machine is not moved on the heavy load roller mechanism. • Only use means of transport (heavy load rollers.e.Transport and installation Procedure: ! Warning When transporting the machine by heavy load rollers. move it by fork lift truck and/or crane as close as possible to its installation site. For this reason. Other forms of transport are not allowed except transporting by forklift truck or by crane! • During machine transport. For this reason. This may also result in material damage to the machine and anything nearby. wrong handling can result in injuries. 4 . ) with a corresponding big intermediate layer (e.Transport and installation ! Caution When transporting the machine by heavy load rollers. • Detach and/or remove all enclosed machine parts (control panel. see the following page. • The subsequent lifting of the machine from the transport pallet and the setting it down on the heavy load rollers must be done by crane. etc. 2. please notify the Hermle AG Service Department at once. hardwood board) on clean contact surfaces and in the way shown • Transport the machine by fork lift truck and/or crane as close to its installation site as possible. please heed the following instructions: • The lifting pad and/or the hydraulic jack may only be applied (see graphic 1 and graphic 2): – – – – – to the described points 3.) from the transport pallet and screw in completely the levelling feet of the electrical cabinet.g. Should any damage be detected. check whether the delivered goods are complete and inspect them for possible damage during transport. in the described order ( 1. • Unscrew the bolted connections holding the machine to the transport pallet (wrench size 24). It is imperative to observe the safety instructions and procedures in the chapters "Transport by fork lift truck" and/or "Transport by crane"! • Please unpack the machine and its components carefully. To continue. . secure both rear heavy load rollers with suitable rubber pads (as shown in figure 1) and put a lifting pad to position (as shown in graphic 2). slide the required support plate (s) between the precision pad and the machine leg prior to lowering the machine. • Pump the machine upward. • Lower the machine vertically. When placing the machine on the front heavy load rollers. • Lower the machine carefully and almost entirely onto the precision pads (it should still be possible to shift the precision pads under the floor contact area). 1. proceed stepwise as described in graphic 1. until you can remove both of the wooden supports. from the top. • If it is necessary to compensate for deviations as set out in the "Dimension sheet for floor evenness at the machine location".Transport and installation • Lift the machine vertically by crane as far as necessary and remove the pallet. If the machine must be put on the heavy load rollers from the floor. Proceed in accordance with the instructions given in the chapter "Arrangement of the precision pads". When doing this. Make sure that the machine does not slip or tilt during the transport! • When the machine stands on its installation site. • Following this. turn the threaded rods by hand. • Place the lifting pad in position 2. Proceed in accordance with the instructions given in the chapter "Transport by crane". evenly and without jerky movements onto the correspondingly positioned heavy load rollers (see illustration 1). secure the rear heavy load rollers with rubber pads against unintentional rolling away (see figure 1)! • Now you can push the machine on the heavy load rollers to its installation site. Position thereupon two precision pads under the floor contact areas of the machine (at the front right and left). • Then lower the machine down completely onto the two front precision pads. make sure that the operating panel be not damaged. Make sure all heavy load rollers point in the direction of travel. (as per graphic 2). through the hole in the floor contact areas into the outer threaded bore of the precision pads. Proceed in accordance with the instructions given in the chapter "Arrangement of the precision pads". Then position a precision pad under the floor contact area of the machine (at the rear right). • Pump the machine upward. lower the machine completely onto the precision pad. • If it is necessary to compensate for deviations as set out in the "Dimension sheet for floor evenness at the machine location".Transport and installation • Pump the machine up. slide the required support plate (s) between the precision pad and the machine leg prior to lowering the machine. • If it is necessary to compensate for deviations as set out in the "Dimension sheet for floor evenness at the machine location". • Lower the machine carefully and almost entirely onto the precision pad (it should still be possible to shift the precision pad under the floor contact area). until you can remove the right rear heavy load roller. lower the machine completely onto the precision pad. • Thereupon apply the lifting pad to position 3. through the hole in the floor contact areas into the inner threaded bore of the precision pad. from the top. (as per Graphics 2). • Then turn the threaded rods by hand. • Then turn the threaded rods by hand. • Finally. • Finally. through the hole in the floor contact areas into the inner threaded bore of the precision pad. until you can remove the left rear heavy load roller. • Lower the machine carefully and almost entirely onto the precision pad (it should still be possible to shift the precision pad under the floor contact area). Then position a precision pad under the floor contact area of the machine (at the rear right). slide the required support plate (s) between the precision pad and the machine leg prior to lowering the machine. Proceed in accordance with the instructions given in the chapter "Arrangement of the precision pads". from the top. . • During the commissioning of the machine. this can lead to damage to the precision pads when the machine is aligned. the Hermle Service Department takes care of screwing down the precision pads completely onto the floor contact areas and performing an exact alignment of the machine.Transport and installation Important Under no circumstances should the precision pads be screwed down completely onto the floor contact areas of the machine! If the precision pads are screwed completely down to the floor contact areas. • Remove the lifting device (four lifting eyes and cross-beam) in the inside of the machine (if necessary. • Place a level on the machine table afterward to make a horizontal check. you can obtain a horizontal alignment of the machine. keep them for a possible later transport – otherwise send them back to Hermle AG). By turning the adjusting screw on the side of the precision pads. . 740 kg approx.Transport and installation Transport of the additional magazines ZM 43 and ZM 1 1 4 3 2 2 Additional magazine 43 Additional magazine Transport weight Additional magazine ZM 43 Additional magazine ZM 87 Enclosure for ZM 43 Enclosure for ZM 87 Transport dimensions Additional magazine ZM 43 (L x W x H) Additional magazine ZM 87 (L x W x H) Enclosure for ZM 43 (L x W x H) Enclosure for ZM 87 (L x W x H) approx. 400 kg approx. 830 kg approx. 400 kg 2000 x 2000 x 2100 mm 2000 x 2000 x 3050 mm 2400 x 1500 x 2000 mm 2400 x 1500 x 2000 mm . make certain to note where the centre of gravity is and to arrange the transporting equipment and lifting tackles accordingly! The transport centre of gravity is identified on the additional magazine / shipping package by the following symbol.Transport and installation Important When transporting the additional magazine.centre of gravity Front view (for ZM 43 and ZM 87) 101 12 3 10 9 Side view (for ZM 43 and ZM 87) 11 9 12 2 10 9 . Transport . • Hermle Service will connect the additional magazine to the machine and align it precisely during the machine start-up procedure.) after the machine has been commissioned. Important Leave the set-up templates included with delivery with the machine in case of possible later transport.Transport and installation Transport information • Set the additional magazine with the transport device down directly next to the machine. • Please return the transport aids (transport device etc. 0 . • Only use means of transport (forklift trucks.) having sufficient lifting power. there is a risk of toppling! • Lift and put down additional magazine only vertically. suspended loads or wrong handling can result in serious injuries or death. lifting trucks etc.e. it is essential to ensure that the forks are inserted far enough into the transport pallet. except transporting by crane! • The additional magazine may be transported by forklift truck only complete with pallet! • The transport bar [3] of the additional magazine may only be used to lift the additional magazine from the pallet! • When driving in the forks into the transport pallet. contact a forwarding company qualified to transport the additional magazine by means of an appropriate forklift truck! Other forms of transport are not allowed. if necessary! 1 . Otherwise. please heed the following instructions: • The transport of the additional magazine by fork lift truck may only be performed by sufficiently qualified personnel or by a forwarding company authorized by the Hermle AG. evenly and without jerky movements! • During transport of the additional magazine.Transport and installation Procedure: Transport by forklift truck ! Danger When transporting the additional magazines by forklift truck. more than the indicated transport weight! • When transporting the additional magazine with the fork lift truck. keep unauthorized persons out of the danger area! • People must never be allowed to stand under heavy loads! • Make certain the transport routes are safe and take appropriate safety measures. i. observe the required: – Minimum lifting capacity of the forklift truck of 3000 kg – Fork length of 100 mm • If no forklift truck meeting the requirements is available on-site. For this reason. • Screw in the adjusting legs included in the delivery in place of the threaded bars [2]. • Carefully lower the additional magazine onto the adjusting legs. • Attach the two reusable pins [4] to the transport bar [3] as right and left lateral arresters. • Unscrew the threaded bars [2] of the additional magazine from the transport pallet. • Drive the forks of the forklift truck under the transport bar [3]. If the additional magazine cannot be positioned directly at the desired installation site using the forklift truck. Proceed in accordance with the instructions given in the chapter "Transport by crane".Transport and installation • Drive the forks of the forklift truck into the transport pallet and carefully lift the entire additional magazine. • Transport the additional magazine to the intended installation site. • Carefully lower the additional magazine to 4 wooden blocks about 30 cm in height. • Insert the transport bar included on the pallet [3] into the openings that before were closed with dummy plugs. • Hermle Service will connect the additional magazine to the machine and align it precisely during the machine start-up procedure. Should any damage be detected. • Lift the additional magazine vertically and carefully by only the amount needed once again and pull the wooden blocks away. • Lift the additional magazine vertically and carefully by only the amount needed and pull the pallet away. the transport of the additional magazine must be continued by crane. 2 . check whether the delivered goods are complete and inspect them for possible damage during transport. please notify the Hermle AG Service Department at once. • Please unpack the additional magazine and its components carefully. i. suspended loads or wrong handling can result in serious injuries or death. lifting frames. • When transporting the additional magazine with the crane. etc.Transport and installation Procedure: Transport by crane ! Danger When transporting the additional magazines by crane.) with sufficient lifting power. please heed the following instructions: • The transport of the additional magazine by crane may only be performed by sufficiently qualified personnel or by a forwarding company authorized by the Hermle AG. if necessary! 3 . more than the indicated transport weight! • To transport the additional magazine by crane. use exclusively a crane crossbeam of suitable design. observe the required: – Minimum lifting force of the crane of 3000 kg – The wire cable or chain set must have a minimum length of 60 cm – The wire rope or chain set must have a minimum lifting capacity of 3000 kg • If no crane meeting the requirements is available on-site. For this reason. keep unauthorized persons out of the danger area! • People must never be allowed to stand under heavy loads! • Make certain the transport routes are safe and take appropriate safety measures. ropes. steadily. contact a forwarding company qualified to transport the additional magazine by means of an appropriate crane! Other forms of transport are not allowed except transporting by forklift truck! • Attach your lifting tackle only to the lifting eye provided for this purpose (lifting device) [1]! • Make sure that the weight is evenly distributed to all lifting tackles! • Lift and put down the additional magazine only suspended horizontally. and without jerky movements! • During transport of the additional magazine. • Only use means of transport and lifting equipment (cranes.e. • Please unpack the additional magazine and its components carefully.Transport and installation • Hang a strand of the wire rope or chain set into each of the lifting eyes (lifting device) [1] on the body of the additional magazine (see illustration). Proceed in accordance with the instructions given in the chapter "Transport by forklift truck". • Screw in the adjusting legs included in the delivery in place of the threaded bars [2]. • Hermle Service will connect the additional magazine to the machine and align it precisely during the machine start-up procedure. 4 . • Carefully lower the additional magazine to 4 wooden blocks about 30 cm in height. • Tighten the transport ropes carefully. please notify the HERMLE AG Service Department at once. • Lift the additional magazine vertically and carefully by only the amount needed once again and pull the wooden blocks away. • Lift the additional magazine vertically and carefully by only the amount needed and pull the pallet away. • Unscrew the threaded bars [2] of the additional magazine from the transport pallet. • Carefully lower the additional magazine to the adjusting legs. Should any damage be detected. transport of the additional magazine must be continued by crane. • Transport the additional magazine to the intended installation site. making sure that the transport ropes are free and will not damage any part of the additional magazine upon lifting. check whether the delivered goods are complete and inspect them for possible damage during transport. If the additional magazine cannot be positioned directly at the desired installation site using the forklift truck. Transport and installation Transport weight Additional magazine ZM 157 approx. 6000 kg Transport of the additional magazine ZM 1 Transport dimensions Additional magazine ZM 157 230 340 10 2330 . Front view 101 20 Side view 101 10 40 .centre of gravity Important When transporting the additional magazine. make certain to note where the centre of gravity is and to arrange the transporting equipment and lifting tackles accordingly! The transport centre of gravity is identified on the additional magazine / shipping package by the following symbol.Transport and installation Transport . • Please return the transport aids (transport device.) after the machine has been commissioned. • Hermle Service will bolt the precision pads to the floor contact areas.Transport and installation Transport information • Set the additional magazine with the transport device and the heavy load rollers down directly next to the machine. . heavy load rollers. connect the additional magazine to the machine and align it precisely during the machine start-up procedure. Important Leave the set-up templates included with delivery with the machine in case of possible later transport. etc. Make sure that the precision pads are positioned in such a way that the adjusting screws for all precision pads are pointing outwards. . For the additional magazine to be lifted from the transport pallet. three spacer plates [2] must be placed between each precision pad and floor contact area. The precision pads must be screwed to the floor contact areas for the additional magazine using the threaded rod [1]. During transport the precision pads of the additional magazine are screwed to the pallet. First. When positioning the precision pads.Transport and installation 1 2 39-1 20 0 200 11 11 109 109 Arrangement of the precision pads Note Hermle Service will attach and adjust the precision pads during the initial machine start-up procedure. use the graphics listed above for orientation. the three precision pads must be unscrewed. Transport and installation Transport by forklift truck and heavy load rollers Graphic 1 00 1400 Fork of the fork lift truck A B Graphic 2 1 2 0 9 . Transport and installation Graphic 3 C D Graphic 4 E E 00 1400 Fork of the fork lift truck 90 . Transport and installation F G F F G Graphic 1 2 91 . suspended loads or wrong handling can result in serious injuries that may become fatal. For this reason. please heed the following instructions: • Transport of the additional magazine by forklift truck and heavy load rollers may only be performed by sufficiently qualified personnel or by a forwarding company authorized by Hermle AG! • Only use means of transport (fork lift trucks. • Lift and put down additional magazine only vertically.Transport and installation Procedure: ! Danger When transporting the additional magazine by forklift truck and heavy load rollers. 92 . 100 mm – Drive-in depth of the forks of the forklift truck between 1800 mm and 2100 mm. Otherwise. evenly and without jerky movements! • During transport of the additional magazine. if necessary! • If the additional magazine is not being moved on the heavy load rollers. observe the following requirements: – Minimum lifting capacity of the forklift truck of 000 kg – Fork length of the forklift truck of min. the heavy load rollers must be secured to prevent it from rolling away unintentionally. Place rubber mats on the forks of the forklift to prevent any damage. contact a forwarding company qualified to transport the additional magazine by means of an appropriate forklift truck! Other forms of transport except transport by crane and heavy load rollers are not allowed! • The additional magazine may only be transported from the left side (with and without transport pallet) (see illustration 1)! • When transporting the additional magazine with no transport pallet be aware of the conduit on the underside of the additional magazine. there is a risk of tipping or damaging the enclosure around the additional magazine! – Minimum load capacity of each heavy load roller of 3000 kg • If no forklift truck meeting the requirements is available on-site. heavy load rollers) with sufficient lifting power.e. i. keep unauthorized persons out of the danger area! • People must never be allowed to stand under heavy loads! • Make certain the transport routes are safe and take appropriate safety measures. more than the indicated transport weight! • When transporting the additional magazine by fork lift truck and heavy load rollers. • Lift the additional magazine vertically and carefully by only the amount needed and pull the pallet away. • Remove all accompanying parts from the transport pallet. If the additional magazine cannot be positioned directly at the desired installation site using the forklift truck. • Please unpack the additional magazine and its components carefully.Transport and installation • Approach with the forklift truck from the left side. The threaded rod [1] must be screwed far enough into the transport bracket [A] so that it still protrudes 0 mm out of the top of the transport bracket [A] (graphic 2)! • Secure each threaded rod [1] by tightening the lock nut [2] down against the heavy load rollers [B] (illustration 2). Make sure that the threaded rod [1] is screwed into the heavy load rollers [B] up to the stop and the lock nut [2] is loose. 93 . check whether the delivered goods are complete and inspect them for possible damage during transport. • Screw in the adjusting feet [C] of the enclosure panels completely and remove the drawbar [D] of the attached heavy load roller vehicle (illustration 3). Should any damage be detected. insert the forks into the transport pallet and carefully lift the complete additional magazine (illustration 1). please notify the Hermle AG Service Department at once. • Fasten the transport bracket provided [A] to the additional magazine and screw the appropriate heavy load rollers [B] with the threaded rod [1] securely to the transport bracket [A]. • Transport the additional magazine to the intended installation site. • Approach with the forklift truck from the left side and insert the forks into the openings [E] provided in the additional magazine (illustration 4). • Loosen all three bolted connections holding the precision pads to the transport pallet. transport of the additional magazine must be continued by crane (refer to the section "Transport by crane") or the heavy load rollers (as described in the following). • Lower the additional magazine carefully and evenly onto the heavy load rollers and make sure that the additional magazine is resting on the heavy load rollers and not on other parts of the machine. • Re-attach the previously removed drawbar to the heavy load roller mechanism. The threaded rod [1] must be screwed far enough into the transport bracket [F] so that it still protrudes mm out of the top of the transport bracket [F] (illustration )! • Secure each threaded rod [1] by tightening the lock nut [2] down against the heavy load rollers [G] (illustration ).Transport and installation • Position the two other heavy load rollers [G] under the two other previously attached transport brackets [F] (illustration ). Otherwise the threaded rods [1] must be screwed correspondingly further into the transport brackets. Leave the heavy load rollers attached to the additional magazine. Make sure that the threaded rod [1] is screwed into the heavy load rollers [G] up to the stop and the lock nut [2] is loose. connect the additional magazine to the machine and align it precisely during the machine start-up procedure. • Now transport the additional magazine to its installation location (close to the machine) on the heavy load rollers. 94 . • Secure the heavy load rollers to prevent them from rolling away unintentionally! • Hermle Service will bolt the precision pads to the floor contact areas. • Screw the two heavy load rollers [G] each together with a threaded rod [1] on the transport bracket [F]. 1100 mm 33 min.Transport and installation Transport with H-frame Transport by crane and heavy load rollers 999 29 1 Lifting eyes (Lifting device) Note To reach the correct rope dimension or to align the machine horizontally. 1440 mm 9 . Always make certain the machine is suspended horizontally on the crane! 4 min. the ropes can also be extended by means of shackles. Transport and installation Graphic 1 Graphic 2 A B 1 2 9 0 . Transport and installation Graphic 3 C D F G F G Graphic 4 1 2 9 . Transport and installation Procedure: ! Danger When transporting the additional magazine by crane and heavy load rollers. ropes. 1440 mm Minimum load capacity of each heavy load roller: 3000 kg • If no crane meeting the requirements is available on-site. heavy load rollers.) having sufficient lifting power. steadily. For this reason. 1100 mm / rear min. if necessary! • If the additional magazine is not being moved on the heavy load rollers.e. suspended loads or wrong handling can result in serious injuries that may become fatal. the heavy load rollers must be secured to prevent it from rolling away unintentionally. 9 . front min. i. and without jerky movements! • During transport of the additional magazine. etc. more than the indicated transport weight! • To transport the additional magazine by crane. please heed the following instructions: • Transport of the additional magazine by crane and heavy load rollers may only be performed by sufficiently qualified personnel or by a forwarding company authorized by Hermle AG! • Only use means of transport and lifting tackle (cranes. contact a forwarding company qualified to transport the additional magazine by means of an appropriate crane! Other forms of transport are not allowed except transporting by forklift truck and heavy load rollers! • Affix your lifting tackle only to the lifting eyes provided for this purpose! • Make sure that the weight is evenly distributed to all lifting tackles! • Lift and put down the additional magazine only suspended horizontally. • When transporting the additional magazine by crane and heavy load rollers. observe the required: – – – – – Minimum lifting force of the crane of 000 kg Minimum load capacity of the crane cross-beam: 000 kg Individual load capacity of each heavy load roller: at least 5000 kg Length of the lifting ropes. use only a suitable H-frame. cross-beams. keep unauthorized persons out of the danger area! • People must never be allowed to stand under heavy loads! • Make certain the transport routes are safe and take appropriate safety measures. transport of the additional magazine must be continued by forklift truck (refer to the section "Transport by forklift truck") or the heavy load rollers (as described in the following). • Loosen all three bolted connections holding the precision pads to the transport pallet. • Remove all accompanying parts from the transport pallet. The threaded rod [1] must be screwed far enough into the transport bracket [A] so that it still protrudes 0 mm out of the top of the transport bracket [A] (graphic 2)! • Secure each threaded rod [1] by tightening the lock nut [2] down against the heavy load roller mechanism [B] (illustration 2). Should any damage be detected.Transport and installation • Insert one of the transport ropes from the crane beam into each of the lifting eyes on the body of the additional magazine (illustration 1). • Transport the additional magazine to the intended installation site. check whether the delivered goods are complete and inspect them for possible damage during transport. Make sure that the threaded rod [1] is screwed into the heavy load roller mechanism [B] up to the stop and the lock nut [2] is loose. • Please unpack the additional magazine and its components carefully. • Tighten the transport ropes carefully. 99 . • Fasten the transport bracket provided [A] to the additional magazine and screw the appropriate heavy load roller mechanism [B] with the threaded rod [1] securely to the transport bracket [A]. please notify the Hermle AG Service Department at once. making sure that the transport ropes are free and will not damage any part of the additional magazine upon lifting. • Screw in the adjusting feet [C] of the enclosure panels completely and remove the drawbar [D] of the attached heavy load roller vehicle (illustration 3). If the additional magazine cannot be positioned directly at the desired installation site using the crane. • Lift the additional magazine vertically and carefully by only the amount needed and pull the pallet away. Make sure that the threaded rod [1] is screwed into the heavy load roller mechanism [G] up to the stop and the lock nut [2] is loose. The threaded rod [1] must be screwed far enough into the transport bracket [F] so that it still protrudes mm out of the top of the transport bracket [F] (illustration 4)! • Secure each threaded rod [1] by tightening the lock nut [2] down against the heavy load roller mechanism [G] (illustration 4). • Re-attach the previously removed drawbar to the heavy load roller mechanism. • Screw the two heavy load roller mechanisms [G] each together with a threaded rod [1] on the transport bracket [F]. connect the additional magazine to the machine and align it precisely during the machine start-up procedure. • Now transport the additional magazine to its installation location (close to the machine) on the heavy load rollers. • Lower the additional magazine carefully and evenly onto the heavy load rollers and make sure that the additional magazine is resting on the heavy load rollers and not on other parts of the machine. Otherwise the threaded rods [1] must be screwed correspondingly further into the transport brackets. 100 . • Secure the heavy load rollers to prevent them from rolling away unintentionally! • Hermle Service will bolt the precision pads to the floor contact areas.Transport and installation • Position the two other heavy load roller mechanisms [G] under the two other previously attached transport brackets [F] (illustration 4). Leave the heavy load rollers attached to the additional magazine. Chapter Machine dimensions and machine weight 101 . Machine dimensions and machine weight C 30 Machine dimension 0 Ejection height of swarf conveyor 1100 mm 00 R 10 20 110 1000 1000 1 In-house connection Electrical 2 1000 Pull-out dimensions: Swarf conveyor 2100 mm Swarf drawer 100 mm 1a R1 3 020 4 440 30 3 340 In-house connection Pneumatic system 110 100 310 340 2940 9 0 10 In-house connection Electrical 140 30 R9 1 0 R 1 0 0 30 144 10 11 2110 0 102 120 030 . A-axis 10 11 2310 1 90 a 103 .Machine dimensions and machine weight 0 0 240 2100 4100 30 3310 30 4 300 440 20 9 10 b 3100 2000 1 Internal Coolant Supply 1a Recooling unit 2 3 4 Swarf cart Swarf conveyor Additional magazine ZM 43 Additional magazine ZM 87 a b Tool handling Driving motor 9 10 11 Additional magazine ZM 157 Cooling unit FLKS 4 or KGL 6 Fluid cabinet Oil mist extraction Standard machine Swivel drive . clamping devices. 9400 kg approx.Machine dimensions and machine weight C 30 Machine weight Total weight of the standard machine C 30 Weight of the additional magazine ZM 157 approx. B. C and D) are based on static measurements at different positions of the milling spindle in the working area (labelled from 1 to 5). 5800 kg C 30 Static load of standard machine Note The following load values of the individual precision pads (labelled A. coolant pan. work pieces. These load values depend on the adjustment of the precision pads and how the machine is equipped! The measurements were carried out on a specific machine model without tools. swarf drawer or options! Switch cabinet D C Basic body of the machine Working area 1 2 4 A 3 B Milling spindle position 1 2 3 4 5 Precision pad / load A ( kg ) 1401 1600 1411 1209 1385 B ( kg ) 1827 1848 2040 1786 1610 C (kg) 1715 1516 1663 1924 1762 D (kg) 3100 3069 2918 3116 3276 104 . 2243 B ( kg ) min. work pieces. coolant pan.Machine dimensions and machine weight C 30 Dynamic load of standard machine Note The following load values of the individual precision pads (labelled A. 3037 808 C (kg) min. clamping devices. C and D) are based on dynamic measurements. These load values depend on the adjustment of the precision pads and how the machine is equipped! The measurements were carried out on a specific machine model without tools. swarf drawer or options! Switch cabinet D C Basic body of the machine Working area A 140 B Precision pad / load A ( kg ) min. 3514 110 10 . 567 max. 3014 611 D (kg) min. max. 379 max. max. B. Machine dimensions and machine weight C 40 Machine dimension 0 00 R Ejection height of swarf conveyor 1100 mm 1000 10 20 110 1000 1 In-house connection Electrical Swarf drawer 1900 mm 1a Pull-out dimensions: Swarf conveyor 2100 mm 2 1000 R1 020 3 4 440 30 In-house connection Pneumatic system 190 100 30 340 34 2940 9 0 10 In-house connection Electrical 10 10 30 R9 1 0 R 1 11 30 0 0 0 144 2300 10 120 3930 10 . A-axis 2310 10 .Machine dimensions and machine weight 0 0 20 2300 4220 30 310 30 90 a 20 4 300 440 9 10 b 3100 1 10 2000 11 1 Internal Coolant Supply 1a Recooling unit 2 3 4 Swarf cart Swarf conveyor Additional magazine ZM 43 Additional magazine ZM 87 a b Tool handling Driving motor 9 10 11 Additional magazine ZM 157 Cooling unit FLKS 4 or BL 058-13 Fluid cabinet Oil mist extraction Standard machine Swivel drive . 5800 kg C 40 Static load of standard machine Note The following load values of the individual precision pads (labelled A. These load values depend on the adjustment of the precision pads and how the machine is equipped! The measurements were carried out on a specific machine model without tools. swarf drawer or options! Switch cabinet D Basic body of the machine C Working area 1 2 4 A 3 B Milling spindle position 1 2 3 4 5 Precision pad / load A ( kg ) 1842 2077 1891 1620 1786 B ( kg ) 1815 1860 2040 1764 1610 C (kg) 2049 1825 2008 2292 2081 D (kg) 3147 3098 2909 3180 3393 10 . work pieces.Machine dimensions and machine weight C 40 Machine weight Total weight of the standard machine C 40 Weight of the additional magazine ZM 157 approx. clamping devices. coolant pan. C and D) are based on static measurements at different positions of the milling spindle in the working area (labelled from 1 to 5). 10700 kg approx. B. coolant pan. 2908 D (kg) min.Machine dimensions and machine weight C 40 Dynamic load of standard machine Note The following load values of the individual precision pads (labelled A. C and D) are based on dynamic measurements. 2698 849 C (kg) min. B. 482 max. 2911 B ( kg ) min. 4175 190 109 . swarf drawer or options! Switch cabinet D C Basic body of the machine Working area A 10 B Precision pad / load A ( kg ) min. 1285 max. 437 max. These load values depend on the adjustment of the precision pads and how the machine is equipped! The measurements were carried out on a specific machine model without tools. clamping devices. max. work pieces. Machine dimensions and machine weight 110 . additional magazine ZM 157) at the desired installation location. pallet changer.Instructions for measuring the evenness of the surface at the machine location (C 30. • [b] Align the levelling rod horizontally and measure the deviations at points E. Measuring surface evenness at the additional magazine location (ZM 157) • [a] Place the levelling rod on the support block at support point "B". • [b] Align the levelling rod horizontally and measure the deviations at points I. . taking into consideration the following dimension sheet. 2. • Enter any deviations in the following dimension sheet in Table 1. 4. C 40) Accessories: • Levelling rod with water level • Measuring stick • Support block 1. J and K relative to "B". PW 160) • [a] Place the levelling rod on the support block at support point "D". G and H for PW 800 in reference to "D". • Enter any deviations in the following dimension sheet in Table 2. 3. C 40) a b • [a] Place the levelling rod on the support block at support point "A". and mark them on the surface. Measuring surface evenness at the machine location (C 30. • Enter any deviations in the following dimension sheet in Table 3. F and G for PW 160 or E. and D in reference to "A". • [b] Align the levelling rod horizontally and measure the deviations at points B. Measuring surface evenness at the pallet changer location (PW 800. C. Designating the machine support points at the machine location Measure all support points (for the machine. F. . C 30 Dimension sheet for surface evenness at machine location Maschinenfabrik Berthold Hermle AG Industriestraße 8-12 D-78559 Gosheim Company: Street/PO Box: Postcode/City: Country: Machine model: Date: Signature: Fax: +49 7426 95-6109 2 J 1 Support point Deviation in +/mm from support point "A" Support plates*) Number 33 1422 Thickness (mm) Machining centre C 30 A 0 B C D 13 02 23 2 13 A +/.0 B K I 241 3 1 12 1991 1329 2 D E 309 C F 2 Pallet changer PW 00 (2a) / PW 10 (2b) E F G H Support point Deviation in +/mm from support point "D" Support plates*) Number Thickness (mm) 1991 12 121 392 2 H 14 E 2a G 3 3 Support point Deviation in +/mm from support point "B" Support plates*) Number + Thickness (mm) Additional magazine ZM 1 I J K 1401 F 2b 34 G - 0-horizontal *) To be completed by Hermle Customer Service . . 0 B K I 2442 3 1 120 219 12 2 D E 209 C F 2 Pallet changer PW 00 (2a) / PW 10 (2b) E F G H Support point Deviation in +/mm from support point "D" Support plates*) Number Thickness (mm) 210 11 131 400 12 H 4 E 2a G 34 3 Support point Deviation in +/mm from support point "B" Support plates*) Number + Thickness (mm) Additional magazine ZM 1 I J K 101 F 2b 44 G - 0-horizontal *) To be completed by Hermle Customer Service .C 40 Dimension sheet for surface evenness at machine location Maschinenfabrik Berthold Hermle AG Industriestraße 8-12 D-78559 Gosheim Company: Street/PO Box: Postcode/City: Country: Machine model: Date: Signature: Fax: +49 7426 95-6109 21 J 1 Support point Deviation in +/mm from support point "A" Support plates*) Number 33 1403 Thickness (mm) Machining centre C 40 A 0 B C D 1 02 21 1 A +/.