Supplied by. Adendorff. Machinery Mart 152Rosettenville Road,Springfield Te 1:(011) ZAY7045FG BENCH MILLING&DRILLING MACHINE.

Transcription

1 Suppled by Adendorff Machnery Mart 52Rosettenvlle Road,Sprngfeld Te :(0) ZAY7045FG BENCH MLLNG&DRLLNG MACHNE OPERATNG MANUAl

2 CONTENTS SAFETY WARNNG SPECFCATON FEATURES NSTALLATON 6 OPERATON ELECTRCAL SYSTEM TROUBLE SHOOTNG MANTENANCE

3 .,.,.. SAFETY WARN NG ---- /. READ ALL NSTRUCTONS BEFORE USNG THS MACHNE 2. KEEP GUARDS N PLACE AND N WORKNG ORDER 3. KEEP WORK AREA CLEAN, CLUTTERED AREA NVTE NJURES 4. KEEP CHLDREN AND VSTORS AWAY FROM WORK AREA 5.DRESS PROPERLY, NO LOOSE CLOTHNG, GLOVES NECKTES,OR OTHER JEWELRY TO GET CAUGHT N MOVNG PARTS, WEAR PROTECTVE HAR COVERNG TO CONTAN LONG HAR. 6. ALWAYS WEAR EYE PROTECTON, ALSO USE FACE OR DUST MASK F OPERATON S DUSTY. 7.REMOVE ADJUSTNG KEYS AND WRENCHES FROM TOOL BEFORE STARTNG. 8. BE SURE DRLL BT OR CUTT NG TOOL S SECURELY LOCKED N THE CHUCK AVOD UNNTENTONAL STARTNG 0. KEEP PROPER FOOT NG AND BALANCE AT ALL T MES, DO NOT REACH OVER OR ACROSS RUNNNG MACHNES.. MA NT A N TOOLS W TH CARE, KEEP TOOLS SHARP AND CLEAN FOR BETTER AND SAFER PERFORMANCE 2. DO NOT OPERATE THS MACHNE WHLE THE NFLUENCE OF DRUG, ALCOHOL OR ANY MEDCATON 3. USE THE RGHT TOOL FOR THE JOB. DO NOT ATTEMPT TO FORCE A SMALL TOOL OR ATTACHMENT TO DO THE WORK OF A LARGER NDUSTRAL TOOL. 4. ENSURE THS MACHNE S PROPERLY GROUNDED 5. SECURE WORKPECE TO KEEP WORKPECE FROM ROTATNG WTH THE DRLL BT OR CUTTNG TOOL 3

4 SPECFCATON Model Max. dr ng capacty Max. face m capacty Max. end m capacty Max. tappng capacty Max. spndle stroke Swvel dameter of spndle Swvel angle of headstock at perpendcular drecton Max. dstance between spndle nose to table Spndle taper Workng area of table Forward and backward travel of table Left and rght travel of table Spndle speeds (4P) / Motor Length j Wdth Overal heght (wthout stand) Net weght/gross weght Standard accessores Optonal accessores ZAY7045FG 40rm, 80rm, 28rm, M4 30mm 680mm + go o 450mm M. T.4 OR RB, 700mmX 240mm or 800rm, X 2 40mm / 75mm [ 400mm or 500mm 50HZ 80,45,260,375,70, 250 RPM 60HZ 95, 75, 30, 450, 850, 500 RPM. 5KW (2HP) l 820mm 060mm or 60mm 060mm 330kg/380kg Wrench MAG 24 A en wrench3mm 4mm, 5mm, 6mm Screwdrver(-) 6" Dr stock Wedge Drawbar Drawbar washer Dr chuck 6mm Face m ng cutter Cl) 76mm Para le vse 90mm or 25mm M chuck Machne stand End m ng cutter Twst drll Cl) 2- Cl) 20mm Cl) -()3. 5mm ;

5 FEATURES () Ths machne may be used for surface cuttng, dr] lng, mllng, and tappng. (2) Ths machne s of fne qualty, can be operated easly, t s not lmted to sklled operator. (3) The drllng and mllng operaton can be performed by two methods: l)hand operaton, whch makes quck feedng drllng. 2)Worm gear feed operaton, whch makes slow feedng mllng. (4) Many of the adjustable nuts are bronze, for adjustng thread clearance and reducng wear. these bronze parts also allow screws to rotate smoothly and mprove accuracy. (5) The vertcal column s very strong and stff, whch makes the machne very stable and mproves accuracy of manufactured parts. (6) The machne headstock s cast ron, t has been heat-treated, stress-releved, and precson machned. (7) Machne gears are precson ground for smooth operaton. (8) Speeds can be easly changed. (9) Tappng can be done n ether rotaton, workng depth can be controlled by usng a postve stop gauge. (0) The head can be turned n two rotaton for a satsfyng desred angle. a " n_ : ;... >.- -- \ : ,,,. square column 2. lock screw 3.rncro feed handwheel 4. lock handle 5. feed handle 6.crank 7. handwheel 8. cross lock screw 9. longtudnal lock screw 0. lock handle.shft handle 2. swtch

6 NSTALLATON () Ensure the headstock s as lower as possble, and be fxed on the column tghtly before movng machne. whle movng machne, keep ts balance and safety. (2) Dont mount the machne at the sunshne place to avod the deformty of machne and the loss of accuracy. (3) Mount machne to a sturdy table or a sold concrete foundaton, ts advsable that the base you choose be well constructed to avod any vbraton durng operaton. (4) Thoroughly clean the machne wth a commercal degreaser, and then coat all brght metal wth a lght lubrcant to prevent corroson. (5) Level the surface of the worktable on both lengthwse and crosswse by usng a precson level. (6) Remove the ol fller plug and fll the ol to the gear box untl the ol level reaches the mddle of the ol flud level ndcator. Lubrcate all ponts OPERATON Notce: Check al parts and safety precautons fo. proper condton before operaton. Use of man machne parts (l)rase and lower the headstock on ts rack and pnon mechansm by usng the head crank. when the desred heght s reached, tghten the bolts to avod vbraton. (2)Head may be rotated 360 by loosenng the same bolts mentoned above. Adjust the head to the desred angle, then tghten the heavy duty head lock nuts. (3)The knob s setted for MLLNG & DRLLNG, TAPPNG AND STOP. The mushroom head red push button for emergency stop whle mllng and dr ng, or reverse whle tappng, the green push button for startng. (4) Feed the spndle usng spndle feedng handle, mcro feed the spndle usng the spndle mcro feedng handle (5)Move the table from sde to sde by usng the lengthwse table feed wheel, and from front to back by usng the cross table feed wheel. 6

7 (6)Adjust the postve depth stop gauge accordng to workng depth. (7)Adjust the.scale sjze accord.ng to,rnrkng need. 2. Dr ng operaton () For dr ng blnd hole (whch do not pass through th workpece), turn off the knob make loose the taper body of worm gear and sprng base, then adjust the postve depth stop gauge so that the dstance from the tp of the drllng bt to the end of the blnd hole s equal to the desred depth. (2)For drlllng pass hoje(whch pass through the workpece),set the postve depth stop gauge n ts uppermost poston. 3. M ng operaton (l)adjust the postve stop depth gauge to ts uppermost poston (2)Lsng the spndle feedng handle, adjust the cutter to approxmately the correct heght, turn off the knob make tghten the taper body of worm and sprng base. (3)Set the workng depth by usng the mcro feedng handle. (4) Lock the rack sleeve at the heght wth the fxed bolt. (5) When longtudnal feedng mllng, t s a good dea to lock the across feedng table to ensure the accuracy of your work. To do ths. tghten the two screws located on the rght sde of the table base. (6) When cross feedng_m_llng,_ lock the longtudnal _feedng _travej., do ths by tghtenng the two screws on the front of the table base. 4. Tappng operaton (l)loosen the knob n the center of the spndle feedng handle. (2)Adjust the postve depth gauge to the requred poston. (3)The swtch pojnt to "tappng". When tappng s overload, press down the red emergency swtch, and the spndle reverse, the taper turn out. 5. Adjustment (l)adjustable moveable fxed rngs are mounted on the front of the table to lmt cross travel. (2)Your machne s equpped wth gb strp adjustment to compensate for wear and excess slack on cross and longtudnal travel. (3)Rotate the gb strp bolt slghtly clockwse to tghten the gb trp. rotate t slghtly counter-clockwse to loosen the gb trp. (4)Adjust the gb trp bolt untl very slght drag s felt when movng the table. 6. Changng machne speed (l)turn the power off. (2)To select the proper speed, move the speed lever to the desred poston. (3)f the gear are not engaged, remove the arbor bolt cover. rotate the spndle slghtly to engage the gears, then replace the arbor bolt cover. (4) Recheck the ever settng, then turn the power on. 7

8 -L -M -H -L J -M ]J -H [ lnstal ng and changng tools WARNNG: BE SURE THE POWER S TURNED OFF AND THE MACHNE UNPLUGGED BEFORE NSTALLNG OR CHANGNG TOOL BTS. (!)Removng face mll or drll chuck arbor. Loosen the arbor bolt at the top of the spndle shaft approxmately 2 turns wth a wrench. rap the top of the arhor bolt wth a ma]] et. After taper has been broken loose, holdng chuck arbor on a hand and turn the arbor bolt wth the other hand. (2)To nstall face mll or cutter arbor nsert cutter and cutter arbor nto the taper of spndle. Tghten arbor bolt secure] y, but do not overtghten. (3)Removng taper drlls (a) Turn down the arbor bolt and nsert thc-. taper dr nto the spndle shaft. (b) Turn -down the rack sleeve untl the oblong hole n -the rack-sleeve--- appears, lock the rack sleeve, nsert wedge though holes and strke lghtly wth a mallet, ths wll force the taper drll out. 8.0rderng replacement parts Complete parts lst s attached, f parts are needed, contact your local d str but or. 9. Addtonal tools and accessores you w fnd helpng Each of machne s equpped wth a M. T. 3 ur RB, contact your local dstrbutor or a man cuttng tool dstrbutor to obtan any of these accessor es. Taper dr Reamers End mlls Cutter arbor Taps Col lets Adapters and sleeves 0.Specfcaton of the T-slot Please refer to fgure, purchase or make T-bolts and other table top fxtures to these dmensons. 8

9 TROUBLE SHOOTNG. The machne doesnt run when the power swtch s turned ON (a)the knob s n the STOP poston (b)a fuse has burned out---check n the sv. tch hox, ancj replace t necessary. (c) Jf there s a surge n the current, the crcut breaker may have opened---press lhe crcut hreaker back, f t s n the open poston. (d)the gear may not be engaged---adjust t..he speed lever to be sure t s engaged. 2. The motor overheats, or there s nsuffcent power (a)the machne s overloaded---reduce the load of feed. (b)the voltage supply s too low---provde wth a relable power supply. (c)the swtch may have a burned or broken contact po n t---replace the swtch. (d)the contactor relay may be broken---replace t. (e)there may be a poor electrcal connecton. Have a qualfed electrcan check the wrng and power supply. (f)the motor s poor---replace wth new one. (g)the drll bt or cuttng blade may be worn---sharpen or replace the bts as needed The spndle bearng_. s ver.y hot. (a)there s nsuffcent lubrcaton---turn off the power,and check the bearng for lubrcaton. f necessary, apply bearng grease. (b)the spndle bearng s worn, or s fxed too tght---turn off the power, unplug the electrcal connecton, and rotate the spndle by hand. Be sure t freely. f not, adjustment the bearng. lf you feel no use n the bearng, you wll have to replace t. (c)the spndle has been turnng at hgh speed for a Jong tme---after Long use, turn the machne off for a whle to gve t a rest, and allow t to cool off. 4. Table travel s not balanced (a) The gap of the table gude s too wde or feel a heavy drag when movng the tahle---adjust gb strp n proper (b) The locked bolts may be loose---check and tghten them f necessary. (c) The feed s too deep---lfoduce the depth of cuttng, make several passes to reach the requred depth. 5. There s vbraton, and roughness of workng surface durng performance. (a)the gap of spndle bearng s too wde--adjust the gap n proper or replace bearng wth new one. (b)spndle loosonng up and down---check the adjustment of the two ()

10 nner bear n covers. adjust them so there s no free play n the taper bearng, and the bearng turns free]y. Tghten them aganst each other to save ths adjustment. (c)the gap of the taper sldng plate s too wdc--adjust the bolt tenson. (d) The chuck s loose---tghten the chuck. (e) The dr bt or cutter s du ---Sharpen or replace t. be sure to use cuttng flud to preserve tool lfe. (f)the workpece s not held frmly--check the clamps or vse you are usng, and assure to tghten the workpece 6. The mcro feed does not work smoothly (a)the clutch may be loose ---Check ths and tghten f necessary. (b) The worm or worm shaft may he worn---check these and rep} ace f necessary (c)the handwheel fxed screw may be loose---check t and tght n f necessary. 7. The workpece s not machned accurately (a) mbalance of heavy workpece---check to see that heavy workpece are held n balance. the workpece Out of balance may shft when beng machned (b) A hammer has been used on the workp ece---never strj ke the workpece wth a hammer. (c) r he table may not -be - - e--_:_::_che.ck-he- tab-l e- ;{th_a_ leve to -- sure t s level both sde to sde and front to back. (d)the machne may not be stable n the floor-- be sure the machne s frmly mounted to the floor. MANTENANCE.After each use (a) Turn off the power swtch. (b) Remove any tool bts, clean and lubrcate them, and return them to ther storage case. (c) Usng a stff brstle brush, brush off all chps. (d) Csng a rag, wpe off any excess or drty ol or cuttng flud left on the machne. (e) Lubrcate the ponts, apply lght greese or ol to all unpanted metal to prevent corroson. (f) Cover the machne to prevent dust or drt contamnaton when not n use. 2.Da ly mantenance (a) Fll the ol reservor to the proper level before each use (b) Check the tghtness of the bolts holdng the head n place. l

11 (c) f overheatng or unusual noses are produced, stop the machne mmedately to check for lack of ]uhrcaton, faulty adjustments, dull tool bts or other defcences, correct any problems before resumng work. (d) Keep the work area clean. 3.Weekly mantenance (a) Clean and coat the lead screw wth ol. (b) Check the lubrcaton of the sldng parts of the table. apply lght greese f needed. 4. Monthly mantenance (a) Adjust the accuracy of the sldes on both the cross and longtudnal feedng. (b) Lubrcate the bearngs, worm gear and worm shaft wth lght grease. 5. Yearly mantenance (a) Adjust the table to assure that t s level n all drectons. (b) Check the electrcal cord, plug, crcut breakers and related connectons to assure that they are secure and safe. (c) Dran the lubrcant from the gear box and replace t. 2

12 ELECTRCAL SYSTEM WARNNG:l.A fuse must be connected between machne and power. 2. The ground termnal of machne must be grounded properly 3.Dont open electrcal box durng operaton, f somethng s wrong wth machne, please ask reparman for help. SPECFCATONS ---- OF THE FUSE Vo ugc ohase Sngle phase llov 220V 380V PH/220VAC/50Hz 20A loa TC FU.2.l. Three phase 5A 5A, " Kr. c: voj \L H< 8 7 PE XL

13 Suppled by Aden dorff Machnery Mart 52Rosettenvlle Road,Sprngfeld Tel :(0) ZAY7045FG BENCH MLLNG&DRLLNG MACHNE PARTS LST

14 /4 SPNDLE ASSEMBL V! l\.

15 SPNDLE ASSENBLY NO. PART No. DESCRPTON QTY. XZ32G Spndle 2 GBff8S8-88 Stop washer 30 3 GBff80-86 Nut M30X.5 4 G Bff Bolt M6X50 5 XZ32G Graduate rod base 6 GBff4-86 NutM6 7 XZ32G Ant-dust cover 8 GB!f Bea rng 30208/P6 9 XZ Rack sleeve 0 XZ32G Rubber flange GBff Bea rng 30206/P6 2 GBff Sprng pn <P3X8 l 3 XZ32G Handle 4 XZ32G Support 5 GB!f Thn nut!\6 l 6 XZ32G Graduate rod t 7 GB{f88-85 Screw M4X6 l 8 XZ32G ndcatng plate 9 XZ32G Set poston l

16 .9- TABLE ASSEMBLY

17 lahl.e ASSENHLY NO. PART No. DESCRPTON QTY. GBff Handle Bl\tOx XZ32G-0-00 Hand wheel 3 3 GB/T73-85 Screw M6xtO 3 4 XZ32G Dal clutch 2 5 GB/T Sprng pn 5x XZ32G Dal rng 2 7 GB/T70-85 Screw M8xt6 6 8 XZ32G Square flange 9 GBffl 8-86 Taper pn 8x J8ff Ol cup 5 GB{f30-94 Thrust bearng XZ32G-l Cross Lead Screw 3 XZ32G Base 4 XZ32G Ant-dust plate 5 GBffS0-88 ut M6xl.5 6 GBff Stop washer 6 7 XZ32G Square column 8 XZ32G Tap gear shaft l 9 GBff30-94 Thrust bearng G Bff Screw M 6x GBff93-87 Sprng washer 4 22 XZ32G Bracket 23 GBff70-85 Screw \6x XZ32G Head handle 25 GBff70-85 Screw!\5x GBff70-85 Screw M8x XZ32G Longtudnal \ ut 28 GBff70-85 Screw M8x45 29 XZ32G-0-0 Adj usta he Screw 6 30 XZ32G-l Cross lead ut 3 XZ32G-l 0-03 Gb strp(short) l 32 GBff Screw J\8x XZ32G-l Moveable fxed block 34 XZ32G-0-02(2) Handle 6 35 XZ32G-0-0J2() Lock screw 6 36 XZ32G Pn 6 37 XZ32G-0-04 Center base

18 TABLE ASSENBL Y NO. PART NO. DESCRPTON QTY. 38 GBff9-86 Pn 8x XZ32G-0-02 Support 40 XZ32G-0-04 Connectve plate 4 XZ32G Taper gear 42 GBff Bearng RS t 43 G Bff Retan rng G Brr Key 5x2 45 XZ32G Screw 46 GBff67-85 Screw M5x XZ32G Cover 48 GBff70-85 Screw M8x40 49 XZ32G Connectve base 50 XZ32G Nut 5 XZ32G Gp strp 52 GBff77-85 Screw MJOxS 53 XZ32G-0-06 Dal clutch 54 XZ32G-0-05 Square flange 55 XZ32G-0-07 Longtudnal lead screw 56 XZ32G Square flange 57 GBff70-85 Screw J\6xt XZ32G-0-08 Moveable fxed rng 2 59 XZ32G-0-09 Fxed block 2 60 XZ32G Table 6 XZ32G Gp strp(long)

19 HEADSTOCK ASSEMBLY :: $ 3 32 l f, ,, ,....,,,.J j j.j f, > 93 / S 3 0 L vjj \ \ z

20 HEADSTOCK ASSEMBLY NO. PART NO. DESCRPTON QTY l 2 3 JBT7l73.l-94 JBT GB/77-85 Handle M6 32 Handqheet u 00 Scrnr M5*8 ] 4 XZ32G-.Je..e Dal seat l 5 GB/f70-85 Sttew M6*4 6 GBT70-85 Screw M XZUG XZ32G GB/fl Cover ::; :a -& s er :_ XZ32G worm shaft JB/f727 l. l-94 BaJ knob MU lj JB/ XZ32G Handle lever BM2*60 Lock bolt wth knob 3 4 XZ32G Sprng base 5 6 XZ32G-30 GB/r Sprng Key 8*22 7 XZJlG Gear shaft l 8 GBT68-85 Screw M5*8 9 XZ32G Worm 20 GB/f70-85 Screw M8 20 J 2 XZ32G-J0-002 Feedn2 box 22 GBT Lock nut M GB/Tl GW93-87 Flud lever ndcator l\.u7*.5 Sprna washer GBT Bott M6* XZ32G Head body 27 GBT Bearng XZ32G Gear GB/fle XZ32G Key 5*25 Slutfl cover l 3 G B/T Bearng GBT Retan rng (erternaj) GBT9877. OU seal B35*62*2 l 34 XZJlG OU fller plug l XZ32G GB/T8-86 Head body cover Taper pn 0* GBT G:erf96-87 GBT 7-86 Key 6*35 Motor Washer8 Screw M8*25 4 4

21 HEADSTOCK ASSEMBL \ NO. PART NO. DESCRPTON QT\: 4 XZ32G Arbor bolt CO"Ver 42 XZ32G Cap l 43 GBff70-85 Screw M8* GB/ ReaJner GBT : -;. "f GB/f lnner rng XZ32G Gear 48 GBT Sprng 2 49 GB/T Steel ball XZ32G Gear 5 XZ32G Gear l 52 GB/T73-85 Screw (5* XZ32G Shaft 54 GBT Key 5 " GB/Tl Key6*2 56 XZ32G Gear 57 XZ32G Gear J 58 GBT Key 6*28 59 XZ32G Gear 60 XZJ2G Shaft 6 GBT Key 6*75 l 62 GBT Key 5*50 63 XZ32G Gear 64 XZ.UG Gear 65 XZ32G Gear 66 GB/T Retan rng(ertemaj) XZJ2G Spacer 68 XZ32G-20-0 Gear 69 XZ32G Spndle sleeve gear 70 GB/T Ke) 6*8 7 GBlf9877. l-88 Ol B35*45* GB/T70-85 Screw \5 " XZ32G Le" er 74 XZ32G Gasket rng 75 XZ32G-20-0J Screw knob J 76 XZ32G Washer l 77 XZ32G Spr.cover 78 XZ3lG Sprng 79 GB!f70-85 Screw M5*0 80 XZ32G Sprng bte

22 HEADSTOCK ASSEMBLY NO. PART NO. D ESC"RPT ON QT\ 8 XZ32G Lock handle 82 GB/T77-85 Screw MO* 0 l 83 GBT79-85 Scrt>w M0 "" 25 J 84 XZ32G-20-04A Fxed tght collar A 85 Xl.J2G B Fxed tght collar B 86 GB/T Gasket rnt[ GB/f70-85 Screw \f2 "".5 l j 88 XZ32G Lever shaft(short) 2 89 GBff894. l-86 Retan rng ( ertemal) GB/T Ol seal B 2 * 22 * GB/f Sprng pn 3 * XZ32G handle 93 XZ32G Fork 2 94 XZ32G Pn shaft ) 95 XZ32G Lever 96 GBrf Sprng pn 4* 2 97 XZ32G Lever

23 PACKNG LST MODEL: ZAY7045FG SERAL NUMBER: NET WEGHT: GROSS WEGHT: 330kg 380kg PACKNG SZE: 880mm X 770mm X l l 60mn No. DESCRPTON SPECFCATONS MACHNE ZAY7045FG 2 STANDARD ACCESSORES Open End Wrench 22 X 24 2 Allen Wrench 3mrn,4mm,5mm,6mm 3 Serew Drver(-) 6" 4 Drll Stock M.T.4 5 \Vedge j6 Draw bar \7 Draw bar Washer 3 OPTONAL ACCESSORES Drll Chuck B6 j2 Parallel Vse 25mm,.,.J Machne Stand 4 Mll Chuck 4-6mrn 5 Face Mllng Cutter 6 Guard cj) 76mm 4 OPERATNG MANUAL 5 PACKNG LST QTY