OPERATION INSTRUCTIONS AMIN TGD

Transcription

1 OPERATION INSTRUCTIONS AMIN TGD

2 Page 2 Index 1 Safety Instructions General safety instructions Safety instructions for grinders Obligations of the owner operator Obligations of the personnel Warranty and liability Explanation of the symbols Complying with the environmental protection regulations 9 2 Intended Use 10 3 Installation 10 4 Starting Up 11 5 Handling Changing the collet chuck 12 6 Technical Drawings and Parts Lists 13 7 Maintenance and Servicing Lubrication of the bearings Parts subject to wear 18 8 Help With Problems 19 9 Scope of Supply Accessories to Special Order Storage Technical Data Disposal Statement of Conformity Warranty Card 22

3 Page 3 1 Safety Instructions 1.1 General safety instructions Read the operation instructions before starting work and follow the instructions in operation. In general, the owner operator of the machine is responsible for ensuring a flawless state with regard to operation and compliance with the safety regulations. The machine has been built to the state of the art and recognized safety rules. Nonetheless, there can be hazards to life and limb to the operator or thirds parties when it is used, or else damage could be done to the machine or other assets. Only use the machine: for the intended purpose, in a flawless state regarding safety. Note the technical data of the machine and the ambient temperatures. The intended use of the machine is described in this documentation in section Intended Use and must be followed. The basic precondition for safe working with and trouble-free operation of the machine is a knowledge of the underlying safety instructions and the safety regulations. In addition, the rules and regulations that apply at the place of use regarding accident prevention, the setting up of electrical and mechanical systems and radio interference suppression are to be followed. Pay attention to the cleanliness of the workplace in all maintenance and repair work. You may not eat or drink while working. If you make any changes on your initiative that go beyond the intended use, the warranty shall be null and void and the manufacturer shall have no liability whatsoever. The machines are not insulated against contact with electric cables and may not be used in an atmosphere with a risk of explosion. It is essential to follow the operation instructions, especially the safety symbols and safety instructions on the machine and in the documentation.

4 Page Safety instructions for grinders Only use approved abrasive wheels with the appropriate diameter of shaft. The approved working speed of the machine tool must be higher than the speed of the grinding or milling machine. Never use a grinding or milling machine that is not in a proper working state or which has defective components. The abrasive wheels must stored and handled with care in accordance with the instructions of the manufacturer. Check the abrasive wheel for damage before using it on the grinding or milling machine. Never use abrasive wheels that are chipped, cracked or damaged in any other way. The machine must be switched off in the event of a power failure. When connecting or disconnecting the grinding or milling machine it is essential to ensure that the operating lever is not and cannot be operated. Disconnect the machine from the power supply when changing the tool. Never remove any safety devices mounted on the machine and ensure that they are attached and working properly before you switch the machine on. Guards or covers are to be adjusted such that they direct sparks and grinding particles away from the body. Strong vibration can be caused by machine tools that are not attached properly or are damaged. Do not use abrasive cutting-off wheels (on machines with a collet chuck). Never exceed the maximum permissible working speed. It must be checked regularly. Before starting up the machine, check that the abrasive wheel has been attached correctly and done up tightly. Carry out a test run for 30 seconds when the machine is in a safe position and not under load. Hold the machine in such a way that the broken pieces could not hit you in the event of a breakage. The machine must be switched off at once if there is considerable vibration or if damage is noticed, and after that the cause for these defects must be found. When working with certain materials it is possible for dust and vapours to be produced that could create a potentially explosive atmosphere. The work pieces must be fixed adequately before starting work. Never use the machine in the vicinity of inflammable liquids or gases. Use suitable facilities at the workplace to keep the air clean if hazardous or explosive dusts, vapours or aerosols are produced. The machine tool can still run on after it has been switched off. Put the grinding or milling machine down in a safe place and wait for it to stop without applying any pressure to the surface. As a matter of principle, use eye protection (EN 166 level B) and ear protection (EN 352). Wear gloves (EN 388 category 2) and protective clothing.

5 Page 5 Depending on the materials being worked with, personal protective equipment and dust extraction must be provided. Do not wear loose-fitting clothing or jewelry. They could be caught up by moving parts. Wear a hair net if you have long hair. Pay attention to the markings, restrictions on use and special notes on use on the abrasive wheel and the grinding or milling machine. Use a suitable abrasive wheel. An unsuitable product can create excessive amounts of grinding particles, dust, vibration and noise. Only use abrasive wheels that meet the highest safety standards. These products carry the relevant number of the EN standard and/or the "osa" marking. Do not exceed the maximum pressure. Use a pressure regulator so the pressure is controlled before it reaches the machine. Abrasive wheels should be stored in such a way that they are not exposed to the harmful effects of moisture, frost and large temperature variations or mechanical damage. Abrasive wheels on substrates should be stored at C and 45-65% relative humidity. Abrasive belts should be stored on a rod or hook of at least 50 mm in diameter. Never use abrasive wheels that have passed their specified "use by" date. Do not change the grinding or milling machine and the abrasive wheels after delivery. Never use force when attaching them. Ensure that suitable chucking flanges are used and that these are in a good mechanical state and free of foreign bodies such as grinding swarf. Only grind with the area of the abrasive wheel intended for that purpose. Avoid grinding with the edges of abrasive belts, use the middle of the belt if at all possible. Abrasive belts that are not being used should be not be kept under tension. Avoid blocking and uneven wear to ensure efficient use of the abrasive wheel. If necessary, dress it regularly. Check the grinding or milling machine each time before use by making a visual inspection to ensure that it is undamaged and suitable for the intended task. The pressure may not exceed 7 bar. Only users with the relevant technical knowledge who have been trained by authorised technicians who are aware of their responsibility may use the grinding or milling machine. Use a respiratory protection mask (EN 149) if the work produces dust. The inhalation of grinding dust can lead to lung damage. Disassembling or assembling our LUKAS grinding or milling machine may only be done by us or an authorized technician. Pay attention to flailing compressed air hoses - risk of injury. Use only the lubricants recommended by LUKAS.

6 Page 6 Take action at once if you feel tingling, stabbing pains or numbness after using the grinder for ten minutes without a break. Avoid using the grinder continuously. Since vibration is felt more strongly under colder conditions, it is advisable to keep your hands warm and to regularly move your hands and fingers. Keep the fastening flanges and abrasive wheels in good mechanical order and replace them if they are worn or deformed. Do not hold the work piece or the machine too tightly in use and do not exert excessive pressure on the abrasive wheel. Worn or defective abrasive wheels must be disposed of according to the relevant national or international regulations. Bear in mind that the abrasive wheels can be contaminated by the grinding process or grinding swarf. Abrasive wheels that have been disposed must be destroyed to prevent them from being reused. If they are provided, use spacers between the abrasive wheel and the chucking flange. Do not do the clamping device up too tightly. Never remove the guards of the machines and ensure that they are in good condition and applied properly. Only start the machine when there is no contact between the work piece and the abrasive wheel. Avoid mechanical damage to the abrasive wheel due to the application of force or impacts or heating up. Note that the maximum permissible working speed must be reduced for small abrasive wheels with a larger open shaft length (lo) between the collet chuck and the wheel (overhang). Follow here the details of the manufacturer of the abrasive wheel or HM milling tool and the specifications of EN Ensure compliance with the minimum clamping length of Lg 15 mm. Lo = open shaft length S = shaft diameter D = abrasive wheel diameter T = abrasive wheel length Lg = clamping length Collet chuck Lg = min. 15 mm There must be no mismatch between the diameter of the abrasive wheel shaft and of the collet chuck. 1.3 Obligations of the owner operator The owner operator is required to ensure that the people who work with the machine

7 Page 7 are familiar with the underlying regulations on safety at work and accident prevention and have been instructed in the handling of the machine, who have read and understood the safety and warning information in these operation instructions and in all other documentation associated with the machine, are checked at regular intervals regarding safe ways of working. Have servicing, maintenance and commissioning work done by a trained technician. Any defects that could affect safety must be dealt with at once. 1.4 Obligations of the personnel All persons working with the machine are always required to comply with the underlying regulations for safety at work and accident prevention, to read and comply with the safety and warning information given in these operation instructions. 1.5 Warranty and liability If nothing is explicitly stated to the contrary, our "General Terms and Conditions of Sales and Delivery" shall apply. Warranty and liability claims arising from injury to persons or damage to assets are hereby excluded if they are due to one or more of the following causes; Inappropriate use of the machine Incorrect assembly, starting up, operation and maintenance of the machine Operation of the machine with defective safety devices or incorrectly applied or non-functional safety and protective devices. Failure to comply with the information given in the operation instructions regarding transport, storage, assembly, commissioning, operation, maintenance and equipping of the machine Making constructional changes or adjustments to the machine that go beyond its normal intended purpose Inadequate monitoring of parts that are subject to wear Repairs, inspections or maintenance work that are carried out incorrectly Catastrophic failures due to foreign bodies and instances of force majeure.

8 Page Explanation of the symbols The operation instructions must have been read before starting work and are to be followed exactly in use. DANGER Warning of direct danger to people. Failure to comply can result in severe or even fatal injuries. Lubricants, coolants and cleaners that are a hazard to the environment must be disposed of safely! NOTE Important or additional information on the machine or the documentation. Eye protection must be used or safety glasses must be worn. Ear protection must be worn. Warning of hand injuries. Warning: Keep your hands away from places that have this warning sign! There is a danger that your hands could be crushed, drawn in or otherwise injured. ESD-protected area The component can be destroyed by an electrostatic discharge.

9 Page 9 Only have maintenance and repair work done on hydraulic, electrical and pneumatic equipment by suitably trained persons and disconnect the electrical machines from the power source! Depressurize the hydraulic and pneumatic equipment of the machine before carrying out any maintenance or repair work! Change the hoses at regular intervals as part of preventive servicing, even if no damage is visible! (Follow the details of the manufacturer.) Before starting up after maintenance or repair work check that all screw connections have been done up tightly and ensure that any tank covers, screens or filters have been put back in place Ensure after finishing the maintenance or repair work and before starting production again that all the materials, tools and other equipment that was required for the maintenance or repair work has been removed from the working area of the machine. any liquids that may have escaped have been removed all the safety devices of the machine function properly. 1.7 Complying with the environmental protection regulations Comply with the legal requirements for avoiding waste and proper recycling/disposal in all work on the machine. Especially when carrying out installation, maintenance and repair work, substances that are a hazard to water such as greases and oils hydraulic oils coolants cleaners containing solvents do not pollute the ground or get into the sewer system. These substances must be stored, transported, collected and disposed of in suitable containers.

10 Page 10 2 Intended Use Grinders with a collet chuck are used with mounted wheels and points and milling tools to machine plastics and metals, for example, in foundries, in die and jig making or in mechanical engineering for deburring, smoothing down weld seams or to machine cast parts. 3 Installation Blow out the compressed air line and hose before connecting the machine. Ensure that all the lines have sufficiently large cross-sections (see section Technical Data) and that the lines are not kinked or pinched. The compressed air hoses should only be longer than 2 m in exceptional cases. This LUKAS angle grinder must be operated with oil-free compressed air (see section Maintenance and Servicing). Connect the grinder as follows: a) for use with unoiled air at a filter regulator consisting of a filter with water separator and pressure regulator. Air consumption Connection thread m 3 /min G ¼ m 3 /min G ⅜ m 3 /min G ½ Use the filter insert for compressed air quality class 3 (Accessories to Special Order - see the table above). Check the flow pressure at the take-off point. The flow pressure must be set to 6.3 bar with the pressure regulator. A higher flow pressure leads to increased wear. If the pressure is too low the performance is reduced. Regarding the quality of the compressed air as per ISO , we recommend: CLASS RESIDUAL OIL mg/m 3 RESIDUAL DUST Particlesize µm max. concentration mg/m 3 RESIDUAL WATER Pressure condensa tionpoint C max. concentration g/m 3 With oiled air With unoiled air ,88

11 Page 11 4 Starting Up Before starting up, insert the abrasive wheel as far as possible into the collet chuck and fasten it using the supplied face spanners (see section Safety instructions). Warning: If the abrasive wheel comes away it can cause injuries. Check that the abrasive wheel has been correctly and securely attached before starting up. Only use approved abrasive wheels. Check whether the permissible rotating speed of the abrasive wheel is greater than that of the grinder. Do not press too hard when working. A high rpm with light pressure is better than a low rpm when pressing hard. When selecting the milling shape and diameter ensure that the radius of the work piece in holes or corners is always greater than the milling tool radius, because otherwise the milling tool can jam and break. When milling in cavities and slots the milling tool should always be moved to and fro a little during the work. Guide the machine such that neither the collet chuck nor the spindle touch the work piece so as to avoid unnecessary wear of these parts and the ball bearings. 5 Handling Only use the machine with due regard to the safety instructions and maintenance stipulations. The machine is started by the rotary valve. IMPORTANT Do not put any oil in the pressure hose, this reduces the performance. Warning The machine can run for a few more seconds after being switched off.

12 Page Changing the collet chuck 1. Disconnect the grinder from the compressed air supply. 2. Hold the 108 with the single-ended open spanner (right-hand thread). 3. Release the chuck with the spanner 601.

13 Page 13 6 Technical Drawings and Parts Lists

14 Page 14 LOCTITE 454GEL LOCTITE 222 LOCTITE 222

15 Page 15 D2,5-GLASS

16 Page 16 Item Description LE part No. 1 SPINDLE COMPLETE A SPINDLE HOUSING (left) A SNAP RING A BALL BEARING 628/8 A NUT A COVER PLATE A TUBE A BALL BEARING X8-2Z (in pairs) A X8 108 SPINDLE A HEAD - SUB-GROUP A O-RING 16 x 1 A COUPLING A HOUSING MOTOR A COMPRESSED AIR MOTOR - COMPLETE A STATOR A BRAKE DEVICE COMPLETE A JET A O-RING A AXIAL DISC A STUD A PRESSURE SPRING A BRAKE DISC A PRESSURE PISTON A ROTOR / DRIVE SHAFT complete A FRONT OUTLET A BALL BEARING X8-2Z (in pairs) A X8 47 REGULATOR COMPLETE A BALL SUPPORT A REGULATOR SCREW A BALL 2.5 glass A REGULATOR HOUSING A LOCKING WASHER 1.9 x 0.5 A DISC A PRESSURE SPRING A O-RING 18 x 1.5 A SLEEVE A ADJUSTING SCREW A SEAL A

17 Page 17 Item Description LE part No. 8 VALVE - SUB-GROUP COMPLETE A VALVE - HOUSING A VALVE A PIN 2.5 x 17 DIN 6325 A STARTER RING A PIN A ADAPTER HOSE A LOCKING RING 16 x 1 DIN 472 A O-RING 11.8 x 2.3 A O-RING 12 x 2 A SCREEN A RING A RETAINING RING A AIR INLET - OUTLET LINE COMPLETE A SHOULDER NUT A SHOULDER SCREWS A NECK SEAL A INCOMING AIR HOSE approx. 2 m A EXHAUST AIR HOSE approx. 1 m A THREADED COUPLER A SILENCER A HOSE COUPLING A DUST CAP 11/15 Vinyl Flex A HOSE CLAMP d=13.3 mm A HOSE CLAMP d=12.3 mm A O-RING 34 x 1 A COLLET CHUCK 3.00 mm A SPANNER SW11 A SPANNER SW 6 / 9 A

18 Page 18 7 Maintenance and Servicing Inspections and maintenance can be carried out by the operator. Incorrect assembly can cause a risk of accidents for the operator and damage to the machine. Compressed air machines require little maintenance in general. Comply with the following rules and the machine will attain the expected long working life and a constantly high level of safety in operation. Check the machine regularly for any external damage. The spindle bearings must be lubricated with oil every hours of operation. We recommend sending the machine to us if there are any problems. 7.1 Lubrication of the bearings 1. Undo the spindle bearings item 1 by hand (left-hand thread). 2. Put 3-5 drops of oil between the coupling and the housing. 3. Install the spindle bearings item 1 (turn them lightly to bring them into place) and tighten up, only hand-tight. Warning The hexagon of the spindle item 108 must fit onto the hexagon of the coupling item 2. Caution The O-ring item 11 must be within the recess in the housing item Parts subject to wear QUANTITY DESIGNATION 1 Brake disc 3 O-ring 2 O-ring 1 Rotor

19 Page 19 8 Help With Problems If problems occur then follow the instructions given in this Technical Documentation regarding your compliance and, if necessary, the corresponding action to be taken. Possible problems and their causes are listed in the following table: PROBLEM CAUSE CORRECTION Insufficient power Operating pressure too low Minimum flow pressure 6.3 bar Choke point in the compressed air line Deal with any constricted sections Hose cross-section too small Use the specified hose diameter Screen holder dirty Clean the screen holder Machine does not No compressed air, cutoff Open the cutoff valve start valve closed Motor runs, but grinding spindle does not turn Coupling broken Replace the coupling Machine cannot be Replace the O-ring O-ring worn stopped If necessary, send the machine to us. 9 Scope of Supply Check the scope of supply for completeness. QUANTITY DESIGNATION 1 Grinder 1 Single-ended open spanner 1 Spanner 1 Collet chuck 3 mm 1 Operation instructions

20 Page Accessories to Special Order DESIGNATION Collet chuck ø 1/8 Collet chuck ø 3/16 Collet chuck ø ¼" Collet chuck ø 4 mm Collet chuck ø 5 mm Collet chuck ø 6 mm 11 Storage Keep unused machines in a dry, enclosed room. 12 Technical Data Technical Data: TYPE AMIN TGD Rpm (no load) (min) Air consumption, under max. load (m 3 /min) 0.43 Air consumption, no load (m 3 /min) 0.17 Rating (kw) 0.25 Weight, without hoses (kg) 0.3 Hose nominal diameter (mm) LW 6 Noise level (db(a)) 74.7 Vibration (m/s 2 ) < 2.5 Length of the incoming and exhaust air hose (m) 2 / 1.25 Flow pressure (operating pressure) (bar) 6.3 Weight - air connection (kg) 0.32

21 Page Disposal Completely disassemble the machine for the required disposal. Separate the materials according to the relevant local and environment-related regulations. Used oil Dispose of used oil in an environmentally-friendly way to avoid damage to the environment. 14 Statement of Conformity In accordance with Annex II A of the EU Machinery Directive 98/37/EU we hereby state that the construction of the pneumatically driven machine maker: Type: LUKAS AMIN TGD Serial No./Machine No.: Year built: complies with the following stipulations: Machinery Directive 98/37/EU Applied harmonized European standards: EN 292-1; EN 1050; EN A1; EN Engelskirchen, 8th August 2007 LUKAS-ERZETT Vereinigte Schleif- und Fräswerkzeugfabriken GmbH & Co. KG Paul Lehnard (Managing Director)

22 Page Warranty Card We hereby grant a warranty in accordance with our written statement of warranty in the operation instructions for a period of 6 (six) months from the date of delivery/sale given below to cover any defects that are demonstrably due to material, design or construction errors and defects for the following machine: Type: Serial No./Machine No.: Year built: Date delivered: Date sold: Stamp: AMIN TGD see invoice date If making a claim under warranty then please send this card to us together with the machine.