E2 Systems BE 481, BE 482, BE 485, BEG 485, BEG 481 User Manual

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Manual

Electro Pneumatic Drilling

And Tapping Unit

Series BE 48 and BEG 48

Read this manual before installation and commissioning of the product. Keep for future reference.

MAN052 - Manual BE 48 and BEG 48, EN, Rev. 02.doc

Table of content: Page:

Table of content 2

Security 3

Description of the Drilling and Tapping unit 4

General and Installation 5, 6, 7, 8, 9

Settings 10, 11

Start-up 11

Tool holders and Cutting tools 12

Drilling, Countersinking and Reaming 12

Tapping 12

Maintenance instructions 13

Oil refilling of the Hydrocheck 14

Drive belt tension and Transmission change out 15

Technical information 16

Dimensional drawing 17

Spare parts drawings 18 and 23

Spare parts lists 19, 20, 21, 22 and 24, 25, 26, 27

Warranty conditions 28

Environmental declaration 28

Security

WARNING!

- Ensure that the operator has read and understood this manual before the unit is in use.

- For security reasons, any modification of the drilling/tapping unit and it’s accessories, which may affect product safety, must be approved by the manufacturers technical manager.

- The unit is intended for drilling, countersinking, reaming and tapping and should not be used for any other application, unless approved by the manufacturers technical manager.

- Always follow local security regulations regarding installation, operation and maintenance.

- The unit must be securely fixed and the installation instructions must be strictly observed.

- The drilling/tapping unit must be protected against splash of emulsions, etc. This is to ensure the units function as the lid for the micro-switches is not sealed against dust or liquid.

- When installing the unit on a stand or in a complete machine tool, necessary protective devices must be fitted to prevent injury caused by crushing (squeezing) or any other type of personal injury that might be caused by the unit or its rotating tool.

- In order to avoid personal injury, the unit's quill must not be run with compressed air in any direction without first mounting safety plates over the limit switches and linear transducer. When changing settings with these plates removed, measures must be taken prevent unintentional movement of the quill, e.g. disconnecting control current or depressurizing the unit's feed cylinder.

- All protective devices that are designed to prevent personal injury must be mounted in their intended position during the operation.

- When servicing or repairing the unit, the electrical system must be switched off and the pneumatic system depressurized.

- Prior to disassembling the unit to change seals etc., the hydrocheck must be fully depressurized. This is most easily accomplished using the bleed screw, See Fig. 15. Pos. 3, on page 14.

- When disassembling the end cover from the hydrocheck, be careful of the spring loaded piston inside the hydrocheck.

- Beware of hands, gloves, hair and loose fit clothing – Watch out for rotating parts.

- Never operate the unit without any eventual safety arrangements – Beware of squeeze risk.

- Make sure that all hoses and electrical wires are safely fastened – Beware of squeeze risk.

Description of the Drilling and Tapping unit

The BE 48-series is a flexible electro-pneumatic unit in a modular design. The electric motor runs the spindle while the feed is pneumatic. An hydraulic feed control (hydrocheck) makes it possible to include functions such as multi wall drilling, rapid advance and automatic chip removal.

The BEG 48-series is a flexible electro-pneumatic unit in a modular design. The electric motor runs the spindle while the feed is pneumatic. An hydraulic feed control (hydrocheck) makes it possible to include functions such as rapid advance. A tapping spindle gives the unit the necessary length compensation.

4 different types of limit switches/position sensors ensure that this unit fits your system design.

Type and speed: See data label on unit Serial number: See data label on unit

1. Spindle with ER32 collet chuck or JT2 taper.

2. Pinole.

3. Oil-level indicator.

4. Regulating valve for controlled feed rate. 0 – 100%.

5. Hydrocheckl.

6. Oil refilling nipple for hydrocheck.

7. 2-way magnetic valve. For linear transducer only.

8. Electric motor. Forward or backward mounted.

9. Feed house.

10. Ports, G1/8''.

11. Mid-section.

12. Limit switches; electric, pneumatic, inductiv or linear transducer.

13. Setting screws for stroke limit.

14. Transmission housing with transmission between electric motor and drive shaft.

General

This Drilling and Tapping Unit is designed for normal drilling, countersinking, reaming and tapping. In applications requiring high-precision hole placement or when drilling into rounded or slanted surfaces, drill bushings must be used.

To be able to use the unit, it must first be installed and fitted with control equipment. Regardless of how simple the installation is performed, the unit must personal injury. Special precaution must be taken to eliminate the risk of clothing, gloves, hair, etc. being caught in the rotating tool.

The unit consists of many components and preassembled parts, the reliability of which is dependent upon proper maintenance. The pneumatic and hydraulic systems include a number of seals. It is essential to keep moving seal surfaces clean and free of marks and scratches.

be fitted with necessary protective devices to avoid

Installation

This Drilling and Tapping Unit is only intended for use in machinery which applies to the Machine Directive 98/37/EG.

WARNING!

Never use the unit without being securely fastened and that appropriate security arrangements have been organised. Be careful with rotating and moving parts, to avoid personal injuries. Ensure that the unit is disconnected from the main air-supply, before any maintenance.

1. We recommend that this unit is installed in a place with clean air and an ambient temperature of

+10 - +40º C (+50 - +104 F.).

2. The unit must always be mounted on a level surface (machined) and attached with six M8 screws. On

the bottom side of the unit = mounting surface, there is a 10 mm wide groove for align the unit. See Fig. 1.

Fig. 1.

3. The protective guards covering the limit switches or linear transducer are not sealed. Make therefore

certain not spray coolant or simliar over them.

4. Connection of the electric motor is done as shown in Fig. 2. and depending on which 3-phase voltage is

available. Check all the data on the electric motors data label to ensure that motor protection and connection are properly carried out. Other types of motors can occure. The electric motor must be equipped with a suitable control circuit and motor protection. The connection cable must have an area of at least 1.5 mm

. Ensure that the motor rotation direction is correct.

Fig. 2.

If the phases L1, L2 and L3 are connected to the terminals as shown in Fig. 2 the motor shaft rotates clockwise, seen against the shaft end on the drive side. Let two of the phase cables change place if the direction of rotation needs to be changed.

Example of control curcuit: One way rotation for drilling and two way rotation for tapping.

Fig. 2a

5. Connection of the feeding cylinder. The connected compressed air must be of good quality.

6 – 7 Bars (87 – 101.5 Psi). Max pressure 8 Bars (116 Psi). The connection is made using an appropriate air preparation unit with air filter and pressure regulator. Oil-mist lubrication is an advantage, but not necessary. The unit is provided with plug-in couplings for plastic hose of Ø8 mm (5/16'') outside diameter for compressed air connection. The inside diameter shall be ø6 mm (1/4''). See Fig. 3.

Fig. 3.

Pos. 1. Port 1, connection thread G 1/8''. Pressurized for forward feed. Pos. 2. Port 2, connection thread G 1/8''. Pressurized for retraction feed.

6. Drilling, countersinking or reaming: The units rapid advance and retraction movements should not

exceed a speed of 100 mm/sec. (0,33 fps) to ensure smooth operation and proper signal processing. This is particularly important when the unit is equipped with a linear transducer. Regulation of the speed is possible by fitting the hoses to the units feed cylinder, Port 1 and 2, with throttle-check valves. Place the throttle-check valves as close as possible to the unit. See Fig. 4a.

Tapping: The rapid advance retraction should not be too high. Regulation of the speed is possible by fitting the hose to the units feed cylinder advance, Port 1, with a throttle-check valve. Place the throttlecheck valve as close as possible to the unit. See Fig. 4b.

Fig. 4a. Fig. 4b.

7. Units delivered with pneumatic limit switches (choosen when ordering) allow automatic drilling operation, pneumatically controlled in accordance with Fig. 5 where the valve (marked Start) is actuated manually. Should repeated automatic drilling be desired, this valve must be replaced by a pneumatically controlled valve which receives its activation signal from the control system of the processing machine in which the unit is installed. Valves are V4 and V5 are pneumatic limit switches, which are delivered mounted on the unit. Valve V1 shall be of 4-way, 2 position type and the the dimension of valve V1 shall be 1/8" when the valve is used for a single

Fig. 5.

8. If the unit is delivered with electrical switches, proximity switches or a linear transducer (choosen when ordering), valve V1 shall be electrically controlled type of 4-way, 2-position type. The dimension of the valve shall be 1/8" when the valve is used for a single

Fig. 6.

unit.

unit. See Fig. 6.

9. Connection of pneumatic limit switches for sensing the position of the feed spindle. The unit is delivered with plastic hose (length 2 meters (6.56 Ft)) with an outside diameter of Ø4 mm (3/16'') for connecting the pneumatic limit switches. Connection, see Fig. 5 and 7.

Fig. 7.

Hose marked, 1: Pressure supply for both limit switches. To be connected directly to the compressed air

system.

Hose marked, 3: Signal for attainment of the set drilling depth. To be connected to maneuvering valve

V1, port no.12.

Hose marked, 6: Signal indicating that the unit is in the retracted position. To be connected to the start

valve, port no.1

10. Connection of electrical limit switches for sensing the position of the feed spindle. Max. capacity 10A at 125 or 250VAC. The unit is delivered with both microswitches connected to a single cable with a length of 2 meter (6.56 Ft). Connection, see Fig. 6. and 8.

Fig. 8.

Microswitch M1 for setting forward direction-reverse position when mechanically non-activated Cable clolur coding: - Between beige and green = no contact

- Between beige and yellow = contact

When the microswitch is activated at the set direction-reverse position: Cable clolour coding: - Between beige and green = contact

- Between beige and yellow = no contact

Microswitch M2 is mechanically activated when the feed spindle is in "home position" = fully retracted: Cable clolur coding: - Between black and blue = no contact

- Between black and brown = contact

- The green/yellow cable is used for earthing.

11. Connection of proximity switches for sensing the position of the feed spindle. The unit is delivered with both switches and with cable lengths of 2 meter (6.56 Ft). Connection, see Fig. 6 and 9.

Fig. 9.

Proximity switch M1 for setting forward direction-reverse position and M2 when the feed spindle is in "home position" = fully retracted. Cable colour coding: - Brown = +24V DC

- Black = Signal

- Blue = 0V DC

12. Connection of the linear transducer for sensing the position of the feed spindle. The linear transducer is a potentiometer, which is delivered with a 2 meter (6.56 Ft) long cable connected to the potentiometer with a PG9 connector, DIN 43650. To facilitate connecting the cable, the leads are marked with their respective numbers as illustrated in Fig. 10. below. Max. voltage for the liear transducer is 40V DC. Connection, see Fig. 6 and 10.

Fig. 10.

Important

Connect the transducer as a voltage divider. The amperage across the potentiometer must not 1 µA. This is no problem if the inner resistance of the analogue IN-port of the measuring device is more then 0,34 MΩ. Should the external control system require greater amperage, an amplifier must be used in accordance with Fig. 11 below.

When the unit is delivered with a linear transducer, the hydrocheck is fitted with a 2-way valve (24V DC) for the transition from rapid advance to working feed. This valve is normally closed, and for rapid advance it shall be supplied with current at the same time as maneuvering valve V1 in Fig. 6. When the output signal from the position sensor matches the set value for the transition to working feed, the current to the 2-way valve is broken. If the unit is fitted with a linear transducer, the external control system must

With the external control system (PLC), the transition from rapid advance to working feed or drilling depth can then be choosen freely by setting the desired value using the control equipment, for example for chip removal or multi-wall drilling.

exceed

Fig. 11.

have an analogue input connection to receive the analogue signal from the position sensor.

Settings

1. Transition from rapid advance to working feed.

Setting the transition on units equipped with pneumatic, electrical or proximity limit switches is performed with a screw, see Fig. 12, Pos. 1, which on return of the feed spindle, retracts the hydrocheck piston rod into position for the next braking. To make it possible to set the transition along the entire stroke length, the unit is delivered with two separate screws of different lengths.

When setting or changing the screw, the feed spindle must be advanced. If this is done using the units compressed air system, the system must be depressurized before setting or changing the screw.

For units fitted with a linear transducer, the hydrocheck piston rod is fixed by screw to the adapter and this follows the movement of the feed spindle completely. Setting is performed using the external control system.

Fig. 12.

2. Drilling depth and forward-reverse position.

For units with pneumatic, electrical or proximity limit switches, the reverse position is set by first making a coarse setting by placing the position sensor, see Fig. 13, Pos. 1, in the right position (4 positions). Then place the cam, see Fig. 13. Pos. 2, in the right groove on the rod. The cam is locked into the groove with a screw. In certain positions the threaded portion of the cam must be screwed out to expose the screw. Setting is then accomplished with the threaded cam. One rotation corresponds to 1 mm (.039 In). See Fig. 13.

For units with a linear transducer, drilling depth and the forward-reverse position are set using the external control system and the analog signal from the position sensor.

Fig. 13.

3. Positive stop.

When more exact drilling depth or reverse position is desired, the positive stop is used. The units control system must then be fitted with a time valve so that the feed spindle continues forward a short time (0,5-2 Sec.) after the pneumatic or electric impulse from the position sensor.

First a somewhat shallower (e.g. 0,5 mm (.019 In)) drilling depth or reverse position is set than that desired in point 2. The drilling depth or reverse position is then set using the adjustment screw, see Fig.

12. Pos. 2, and locked into position with a lock nut. Please note that the impulse from the position sensor must be received before the feed spindle reaches the positive stop.

4. Working feed rate.

Setting the limit for the working feed rate is performed using the valve on the hydrocheck. The adjustment is from 100% (full open) down to 0%. See Fig. 14, Pos. 1.

ONLY, adjust the working feed rate when the spindle is in “home position”.

Fig. 14.

Start-up

1. Ensure that the responsible operator has read and understood the manual before start-up of the unit.

2. Ensure that the safety measures in chapter "Security" are met before the start-up of the unit.

3. Follow possible local safety regulations.

4. Ensure that the installation is performed as described in chapter "Installation".

5. Check that the spindle rotates in the right direction.

6. Before starting check the setting of the transition to the working feed so that the tool does’nt enter the

workpiece at rapid speed.

Tool holders and Cutting tools

The unit can be equipped with the following tool holder types: (Choosen when ordering.)

Key Chuck: Drill Chuck: Tapping spindle: Collet Chuck: Collet with compensation

The following cutting tools can be used with drilling or tapping unit:

Drilling unit BE 48: Drills, Core Drills, Shank Mills, Countersinkers, Reamers or Brotsch. Tapping unit BEG 48: Cutting Taps or forming Taps.

Drilling, Countersinking and Reaming

1. The transition from rapid advance to working feed must be set, see chapter “Settings” paragraph 1, so

that a margin of safety is provided allowing the speed to change to working feed before the tool reaches the workpiece. Measure the distance from the leading edge of the tool to the workpiece and set the distance in accordance with, Fig. 12, Pos.3 for a somewhat shorter distance. Note! When the unit is equipped with a linear transducer, consideration must be taken to the reaction time of the valve so that the value set using the external control system is sufficiently shorter than the measured distance to allow braking.

2. Drilling depth and forward-reverse position should be set in accordance with chapter “Settings” par. 2.

3. Should the air pressure used on the feed cylinder result in a working feed rate that is too high, limit the rate in accordance with chapter “Settings” paragraph 6.

Tapping

Tapping may be performed using a reversing die head or by reversing the tapping units electric motor. Please note, that when reversing the electric motor, a tapping spindle with an axially floating tap holder must be used.

1. When tapping, set the working feed rate at a somewhat lower value than that of the speed of the tap.

Tap speed can be calculated in accordance with the following: Rpm: 60 x pitch in mm = mm/sec. Measure a distance and divide it by the measured time to determine the speed.

2. Tapping depth is then set using the forward-reverse position. See chapter “Settings” paragraph 2.

Note! When setting, the working feed rate must not be altered, as this will affect the tapping depth. When tapping with a tapping spindle, the signal for reversing the electric motor must be given when the feed spindle reaches the forward-reverse position.

3. The retraction rate of the feed spindle must be adapted to the speed of the tap at withdrawal to prevent

the axial movement of the die head or the tapping spindle from hitting bottom during retraction. The speed is regulated using a throttle-check valve in accordance with chapter ”Settings” paragraph 6.

4. When tapping short lengths where the axial movement of the die head or tapping spindle take up the

entire tapping length, the feed spindle can be run to the positive stop after the tap strikes the piece and then commence retraction after a predetermined time.

5. When using low retraction rates it may be necessary to delay initiation of the electric motors rotation for

withdrawal of the tap. This is due to the fact that air pressure in the plus chamber of the feed cylinder must have time to drop for the feed spindle to retract.

Maintenance instructions

Daily inspection:

1. Ensure that the unit is free of chips and dirt that can cause disruption.

2. Ensure that the unit is running smoothly and that it is not making any unusual sounds. In the event of

any abnormal noise, immediately stop the machine and cal for service staff to rectify the fault.

3. Check that there is no external leakage on the hydrocheck. In the event of leakage, immediately call for

service staff to rectify the fault and then refill oil. See chapter ”Oil refilling of the Hydrocheck”.

Monthly inspection:

1. Check the oil level in the hydrocheck using the green oil-level indicator, see Fig. 15. Pos 1.

At max. oil level, the indicator is completely visible, and when only 2 - 3 mm (.078 – .118 In) are showing it is advisable to add oil. If the green indicator is inadvertently depressed, it can be reset by manually pulling it out again. To grip the indicator pin, loosen the hexagonal protective sleeve. For refilling of oil see chapter ”Oil refilling of the Hydrocheck”.

2. Check the belt drive for wear and proper tension, see chapter ”Drive belt tension and Transmission

change out“.

3. Check the locking of the settings:

- Adjustment screw for transition to working feed. (Applicable for pneumatic, electric and proximity limit switches.)

- If linear transducer, sleds attachment to the adapter.

- Drilling depth and forward-reverse position.

- Positive stop.

- Working feed rate.

Annual inspection:

In addition to the daily and monthly inspections, the following points should be observed.

1. Check the units pneumatic feed system for:

- External leakage.

- Leakage at the piston seal by performing the following. Advance the feed spindle to the positive stop with out activating the signal for the forward-reverse position and check that there is no leakage of air on the minus side. Note! Disconnect the hose to port 2, see Fig. 3 on page 6. Check correspondingly for leakage at the piston seal when the feed spindle is in ”home postion”.

- Check that the feed spindle advances and retracts at an air pressure of 2 Bars (29 Psi). Without feed control the feed spindle should advance and retract at 1 Bar (14.5 Psi).

In the event of leakage or if the feed spindle is sluggish, the feed system should be dismantled and

cleaned and all seals should be replaced. Note! When reassembling, lubricate bushings, seals, and the cylinder barrel with a suitable grease.

2. Check the hydrocheck for:

- Scratches or marks on the hydrocheck piston rod.

- Leakage at the piston by lowering the working feed rate to 0 and checking that the feed spindle practically stands still.

- Advance and retraction of the hydrocheck at 2 Bars (29 Psi) pressure. See paragraph 1 above.

In the event of leakage or problems with any of the above mentioned points, the hydrocheck should be

dismantled and cleaned and all seals and damaged parts should be replaced. For refilling of oil see chapter ”Oil refilling of the Hydrocheck”.

3. Check the lubrication of the drive shafts splines by separating the belt housing from the mid-section.

Note that in certain cases the pulley on the drive shaft must be removed, see chapter ”Drive belt tension and Transmission change out“. If necessary, lubricate the splines with a suitable grease.

Oil refilling of the Hydrocheck

Suitable oil quality: Hydraulic oil with a viscosity of e.g 32 cSt at +40º C (+104 F) and a high viscosity

index e.g. 345. Recommended oil: Castrol, Hyspin AWH-M 32 acc. to ISO VG32.

Oil quantity (filled): Ca 6,3 cl (2.22 fl.oz. (UK), 2.13 fl.oz. (US))

Oil refilling equipment: Part. no. 043J400426

1. When filling oil the feed spindle should be fully extended so that the hydrocheck piston rod

is fully retracted.

2. If, for some reason, the green level indicator, see Fig. 15. Pos. 1, is fully visible when filling oil, it should

be depressed manually.

3. Connect an oil injector to the oil filling nipple, see Fig. 15. Pos. 2, and fill oil until the green indicator pin

is nearly completely extended again. Note! Discontinue filling just before the pin is completely extended to avoid excessive pressure in the system.

4. Whenever the hydrocheck has been disassembled or if air has entered the oil system, The system must

be bled when filling oil. The hydrocheck must then be turned so that its piston rod is facing upwards as oil is being filled and the system is bled using the screw shown in, see Fig. 15. Pos. 3. Note! The piston rod must be completely depressed while filling oil. Begin filling with the bleeding screw open and when the oil stream is air-free, tighten the screw. Then fill with oil until the indicator pin Pos. 1 is extended.

WARNING!

Fig. 15.

Belt tension and Transmission change out

1. Belt tension must not be too great. Slide the tensioning pulley carefully against the belt and lock with

the screw in its center. Proper belt tension has been attained when the belt can be depressed approx. 20 mm (13/16'') with light pressure. See Fig. 16.

2. When changing the transmission, first loosen the centre screw for the respective drive pulley. The pulley

can be kept from rotating by mounting two screws (M6) in the threaded holes in the pulley and using a metal bar. Then loosen the tensioning pulley and remove the belt. Use a puller to remove the drive pulley if it cannot be loosened by hand. When removing the larger pulleys it may be too tight to use a puller. In such cases the threaded holes can be used to mount a strip of steel plate with a screw in the middle to press loose the pulley.

Fig. 16.

Technical information

Technical features, at 6,3 Bar (91.35 Psi):

Thrust : BE(G) 481 Max. 1650 N BE(G) 482 and BE(G) 485 Max. 2000 N Stroke : Max. 100 mm (3 15/16''), 100% controlled. Min. center to center spacing : Single spindle min. 90 mm (3 9/16'') Double spindle head min. 11 mm (7/16'') Run-out at spindle nose : Max. 0,02 mm (.0008 In) Depth accuracy : +/- 0,01 mm (.0004 In) Rapid advance rate : Max. 10 m/min (390 In/min) Controlled feed rate : > 0,04 m/min (> 1.6 In/min) Power, Electric motor : See Power, Electric motor specifications below. Air supply : 6 – 7 Bar. Max 8 bar (87 – 101.5 Psi. Max. 116 Psi) Air consumption : < 2,8 l/ 100 mm (< 3/4'' Gallon/4'') Ambient temperature : +10º - +40º C. (+50 - +104 F.) Sound level : 85 dB(A)

Power, Electric motor specifications:

poles

2 0,55 0,75 1,65 4 0,37 0,55 1,1 6 0,25 0,32 0,75 8 - - 0,4

Unit/Motor at V380-420(Y) / 220-240(∆) (±5%), 50Hz. kW * No. of

BE(G) 481

BE(G) 482

Transmission specifications:

Drilling unit BE 48:

No. of poles

2 4 6 8

Spindle rpm at gear ratio and 50Hz.

2,5:1 2,1:1 1,8:1 1,6:1 1,4:1 1,2:1 1:1 1:1,2 1:1,4 1:1,6 1:1,8 1:2,1 1:2,3 1:2,5

1130 1350 1580 1750 2090 2420 2820 3290 3810 4550 5040 5880 6460 7170

560 670 780 860 1030 1190 1390 1620 1880 2240 2480 2900 3190 3530

360 440 510 560 670 780 910 1060 1230 1470 1630 1900 2090 2310

270 330 380 420 500 580 680 790 920 1100 1210 1420 1560 1730

1:2,8 1:3,1 1:3,4

7760 8600 9450

3820 4240 4660

2500 2780 3050

1870 2070 2280

Tapping unit BEG 48:

No. of poles

2 4 6 8

Spindle rpm at gear ratio and 50Hz.

2,5:1 2,1:1 1,8:1 1,6:1 1,4:1 1,2:1 1:1 1:1,2 1:1,4 1:1,6 1:1,8 1:2,1 1:2,3 1:2,5

1130 1350 1580 1750 2090

560 670 780 860 1030 1190 1390 1620 1880

360 440 510 560 670 780 910 1060 1230 1470 1630 1900

270 330 380 420 500 580 680 790 920 1100 1210 1420 1560 1730

1:2,8 1:3,1 1:3,4

1870

For other data such as drilling capacity we refer to our website www.e2systems.com.

* Motor specifications shown in

BE(G) 485

the tables are valid for 380 – 420V(Y)/220 – 240V(∆) (±5%), 50 Hz. These motors can also be used at 440 – 480 V(Y) (±5%), 60 Hz. If so the rpm will increase by ~20% and the power by ~15% relative to the data for 50 Hz.

The torque at the spindle for specific rpm is calculated as: M = ( P

(kW)

x 9500 ) / rpm

Dimensional drawing

Multi-spindle head, type A mm B mm C mm D mm Adaptor,

MBKV-402

VH 042P/ 043P / 043LP / 044P

MBK-6V2

MBK-6V3 / 6V4

MBKV-6VR3

MBKV-602 / 603 / R603 / 604

VH 062P / 063P / 063LP / 064P

MBKV-802 / 803 / R 803 / 804

VH 082P / 083P / 083LP / 084P

VH 102P / 103P / 103LP / 104P

MBKV-1002

20 35 117 95 1,2 2,65 22 25 97 98 1,2 2,65 21 56 117 91 1,2 2,65 21 56 121 98 1,2 2,65 21 56 137 98 1,2 2,65 21 35 127 98 1,2 2,65 25 34 136 98 1,2 2,65 34 40 144 107 1,2 2,65 28 40 148 98 1,2 2,65 28 40 162 104 1,2 2,65 27 35 163 107 1,2 2,65

weight

Kgs

Adaptor,

weight

Lbs

Spare parts drawing

Spare parts list

BE(G) 481, BE(G) 482 and BE(G) 485

Pos. Qty Description Part no.

1 1 Feed housing, complete. See pos. 125

2 1 Seal kit for quill with JK2 spindle, complete. See pos. 120

2 1 Seal kit for quill with ER32 spindle, complete. See pos. 129

3 1 Slide bearing See pos. 124

4 2 Expander plug MB 800-060 See pos. 125

5 2 O-ring, 69,5x3 Nitril

6 1 Front plate See pos. 124

7 9 Screw, MC6S 8x30 FZB See pos. 121

8 1 Piston rod seal

9 2 Ball bearing See pos. 126

10 1 O-ring, Ø35,1x1,6 Nitril See pos. 120/126

11 1 Spindle nut 043V400349

12 1 V-ring, V18 A See pos. 120/126

13 1 Nut 043V400348

14 1 Spindle with B12 taper, complete. 043R000016

14 1 Spindle with JT2 taper, complete. 043R000017

14 1 Spindle ER32 collet chuck, complete. 043R000024

15 1 Spindle nut 413A112025

16 1 Quill 043V300163

17 4 Screw, MC6S 5x20 8.8 FZB 411A121115

18 1 Ball bearing See pos. 125

19 1 Piston 043V400350

See pos. 120/124/129

20 1 Piston rod gasket See pos. 120

21 1 O-ring, Ø50x3 Nitril See pos. 120/129

22 1 Cushioning washer 043V400372

23 1 Button See pos. 122

24 4 O-ring, Ø5,1x1,6 Nitril See pos. 120/129

25 1 Slide bearing See pos. 122

26 1 Guide tube 043V300164

27 1 Piston rod seal See pos. 120/129

28 1 Mid-section See pos. 122

29 2 Ball bearing 419A100014

30 1 Drive shaft 043V300158

31 1 Belt housing 043V100009

32 1 Spacer 043V400347

33 5 Screw, MF6S 4x12 FZB 411A121038

34 1 Locking washer 043V400346

35 1 Spacer 043V400354

Pos. Qty Description Part no.

36 1 Key, TK 6x6x22 415A141010

37 1 Washer 043V400396

38 1 Screw, MC6S 8x20 FZB 411A122028

39 4 Screw, MC6S 8x90 8.8 FZB 411A122045

40 1 Tension roll See pos. 123

41 1 Screw, MC6S 8x40 8.8 FZB 411A121155

42 2 Washer, BRB 8,4X17X1,6 414A112011

43 2 Ball bearing See pos. 123

44 1 Circlip, SGH 32 See pos. 123

45 1 Lid 043V200022

46 1 Foil 043V400343

47 1 Nut, M6M M8 FZB 413A112016

48 1 Tension shaft 043V400345

49 4 Screw, MF6S 4x10 FZB 411A121001

50 1 Motor lid for -71 electric motor. BE(G) 481 and BE(G) 482 043V300160

50 1 Motor lid for -80 electric motor. BE(G) 485. 043V300159

51 4 Screw, MC6S 6x16 FZB 411A122039

52 10 Screw, MC6S 5x16 FZB 411A121114

53 1 Screw, M6S 6x60H 8.8 FZB See pos. 127

54 1 Screw, MC6S 6X25 8.8 FZB 411A121142

55 2 Nut, M6M M6 FZB See pos. 127/128

56 1 Transducer ring See pos. 130

57 1 Grub screw, P6SS 4x5, svart See pos. 130

58 1 Setting nut See pos. 131

59 1 Setting body See pos. 131

60 1 Pressure spring, 1x8x25 See pos. 131

61 1 Grub screw, P6SS4x4 See pos. 131

62 1 Transducer rod 043V400360

63 2 Air connection 043V400351

64 4 Screw, MC6S, 4x20 FZB 411A122017

65 1 Cross head See pos. 121

66 1 Slide bearing See pos. 121

67 1 Support shaft 043V400342

68 1 Screw, T6SS 5x8 FZB See pos. 122

69 1 List 043V400359

70 2 Screw, MC6S 4x10 FZB 411A121101

71 1 Screw, P6SS 5x5 FZB 411A151024

72 1 Clamp 043V400356

73 1 Cover plate 043V300172

74 1 Cover plate 043V300173

75 7 Screw, MC6S 4x6 FZB 411A122015

76 1 Bottom plate 043V400364

Pos. Qty Description Part no.

77 2 Proximity switch, inductive, 24 V DC. 604A000006

77 2 Micro switch, pneumatic. 604A000011

77 2 Micro switch, electric, 10A 125V AC / 10A 250V AC. 604A000012

78 4 Screw, MC6S 3x16 FZB 411A121095

79 2 Rivet 415A122001

80 1 Data label 417S900050

81 1 Cable gland, for pneumatic switches 418A264001

81 1 Cable gland, for electric and proximity switches 418A260001

82 1 Y-connector 057Y000001

83 1 Plastic hose PA 11, length 2 meter ( 6.56 Ft) 057G000002

84 2 Coupling, G1/8-8 057E010818

86 1 Cable, 7x0,25, length 2,15 meter (7.05 Ft) 514A000001

87 4 Screw, MF6S 4x10 FZB 411A121001

88 2 Linear stay 043V400365

89 2 Screw, MC6S 4x8 FZB 411A121007

90 2 Dog 043V400352

91 2 Insulation plate 604A000013

92 1 Cover plate 043V300175

93 1 Cover plate 043V300174

95 1 Blind lid 043V200028

96 1 Lid 043V200029

97 2 Screw, MC6S 5x16 FZB 411A121114

98 1

Linear transducer with plug PG 9, DIN 43650 and cable 2 m (6.56 Ft).

604A000005

99 1 Spacer 043V400370

100 1 Screw, MC6S 6x35 FZB 411A121139

101 1 Screw, MC6S 4x22 FZB 411A121006

102 1 Linear clamp 043V400361

103 1 Motor, BE(G) 481, 0,55 kW, 2820 rpm at 50Hz, M2VA 71 B 508A000103

103 1 Motor, BE(G) 482, 0,75 kW, 2820 rpm at 50Hz, M2VA 71 BC 508A000110

103 1 Motor, BE(G) 485, 1,65 kW, 2820 rpm at 50Hz, M2VA 80 C 508A000123

103 1 Motor BE(G) 481, 0,37 kW, 1390 rpm at 50Hz, M2VA 71 B 508A000112

103 1 Motor, BE(G) 482, 0,55 kW, 1390 rpm at 50Hz, M2VA 71 C 508A000126

103 1 Motor, BE(G) 485, 1,1 kW, 1390 rpm at 50Hz, M2VA 80 C 508A000127

103 1 Motor, BE(G) 481, 0,25 kW, 910 rpm at 50Hz, M2VA 71 B 508A000131

103 1 Motor, BE(G) 482, 0,32 kW, 910 rpm at 50Hz, M2VA 71 C 508A000138

103 1 Motor, BE(G) 485, 0,75 kW, 910 rpm at 50Hz, M2VA 80 C 508A000137

103 1 Motor, BE(G) 485, 0,40 kW, 680 rpm at 50Hz, MT 80 C 508A000146

104 1 O-ring, Ø13,95x2,62 Nitril See pos. 129

105 1 Ball bearing 419A100038

106 1 O-ring, Ø64,2x1,6 Nitril See pos. 129

107 1 Nut 413A119015

108 1 Front nut 043V400459

Pos. Qty Description Part no.

109 1 Radial seal, R38x55x7 See pos. 129

110 1 Setting screw 043V400461

111 1 Tension nut ER32 043K000004

112 1 Bearing housing 043V300226

113 1 Spindle 043V200038

114 1 Quill ER32 043V300225

115 1 Adaptor for multi spindle head VH042. 043V300190

115 1 Adaptor for multi spindle head VH062, VH063, VH082 and VH083. 043V300194

115 1 Adaptor for multi spindle head VH0102. 043V300195

115 1 Adaptor for multi spindle head VH043. 043V300199

115 1 Adaptor for multi spindle head VH0103. 043V300203

115 1 Adaptor for multi spindle head VH13X and VH18X. 043V300461

115 1 Adaptor for multi spindle head VH181. 043V200050

116 1 Drive adaptor for VH042/043, 062/063, 082/083 and VH181. 040V400077

116 1 Drive adaptor for VH102/103 and VH13X/18X. 040V300091

117 1 Screw, MC6S 8x30 FZB. 411A121153

118 4 Screw, MC6S 6x25 FZB, for VH042, VH062 and VH082. 411A122004

118 3 Screw, MC6S 6x25 FZB, for VH043, VH063 and VH083. 411A112004

118 4 Screw, MC6S 8X30 FZB, for VH102. 411A121153

118 3 Screw, MC6S 8X30 FZB, for VH103. 411A121153

118 4 Screw, MC6S 8x40 8.8 FZB, for VH13X and VH18X. 411A121155

118 4 Screw, MC6S 8x35 8.8 FZB, for VH181. 411A121139

119 1 Screw, MC6S 4x20, for VH042/043, 062/063, 082/083 and VH181. 411A122017

119 1 Screw, MC6S 4x25, for VH102/103 and VH13X/18X. 411A121104

120 1 Sacer washer PS 414A131020

Complete kits.

120 1 Seal kit for quill with JT2 spindle, complete. 043R000002

121 1 Dog for hydrocheck, complete. 043R000006

122 1 Mid-section, complete. 043R000007

123 1 Tension roll, complete. 043R000008

124 1 Front plate, complete. 043R000009

125 1 Feed housing, complete. 043R000012

126 1 Bearing kit for spindle, complete. 043R000013

126 1 Stop screw kit, complete. 043R000014

127 1 Rapid advance screw kit, complete. 043R000015

129 1 Seal kit fpr quill with ER32 spindle, complete. 043R000018

130 1 Transducer ring, complete. 042R005008

131 1 Adjusting nut, complete. 042R005010

135 1 Conversion kit, from JT2 spindle to ER32 spindle, complete. 043R000023

136 1 Convesrion kit, from ER32 spindle to JT2 spindle, complete. 043R000025

Spare parts drawing

Pos. Qty Description Part no.

1 1 Hydrocheck without magnetic 2-way valve, complete. 043A200036

1 1 Hydrocheck with magnetic 2-way valve, complete. 043A200037

2 1 End cover for hydrocheck without magnetic 2-way valve, complete. 043R000004

2 1 End cover for hydrocheck with magnetic 2-way valve, complete 043R000003

3 1 Piston rod, complete. 043R000005

4 1 Level protector 043V400363

5 2 O-ring, Ø5,1x1,6 Nitril See pos. 40

6 1 Level indicator 043V400338

7 1 Guide 043V400334

8 1 Screw, MC6S 4x35 FZB 411A121106

9 1 Spring 416A111042

10 1 Spring guide 043V400333

11 1 Piston seal See pos. 40

12 1 Piston 043V400336

13 1 O-ring, Ø31,4x1,6 Nitril See pos. 40

14 4 Screw, MC6S 6x35 FZB 411A121139

15 1 Bushing 043V400332

16 1 O-ring, Ø19,1x1,6 Nitril See pos. 40

17 1 Piston seal See pos. 40

18 1 Scraper seal See pos. 40

19 1 Directional valve, 2-way 043K000001

20 1 Magnetic coil, 24V DC 043K000002

21 1 Knob 043V400436

22 1 Circlip, SGH 28 415A151012

23 1 Regulating spindle 043V400439

25 1 O-ring, Ø22,2x3,0 Nitril See pos. 40

26 1 O-ring, Ø27,1x1,6 Nitril See pos. 40

27 1 Regulating body See pos. 39

28 1 Filter See pos. 39

29 1 O-ring, Ø14,1x1,6 Nitril See pos. 40

30 7 Expander plug, MB 800-600 See pos. 1

31 1 Screw, T6SS 5x8 411A151151

32 1 Oil refilling nipple 043K000003

33 1 Expander plug, MB 800-070 See pos. 3

34 1 O-ring, Ø13,1x1,6 Nitril See pos. 40

35 1 Piston See pos. 3

36 1 Ball See pos. 3

37 1 Spring See pos. 3

38 1 Piston seal See pos. 40

39 1 Adjustment valve, complete. 043R000022

40 1 Seal kit for hydrocheck, complete. 043R000020

Pos. Qty Description Part no.

41 1 Plug PG9, for magnetic 2-way valve, DIN 43650 033J339000

50 1 Transmission kit, BE(G) 481, BE(G) 482; 2.5:1, complete. 043A500017

50 1 Transmission kit, BE(G) 481, BE(G) 482; 2.1:1, complete. 043A500016

50 1 Transmission kit, BE(G) 481, BE(G) 482; 1.8:1, complete. 043A500015

50 1 Transmission kit, BE(G) 481, BE(G) 482; 1.6:1, complete. 043A500014

50 1 Transmission kit, BE(G) 481, BE(G) 482; 1.4:1, complete. 043A500013

50 1 Transmission kit, BE(G) 481, BE(G) 482; 1.2:1, complete. 043A500012

50 1 Transmission kit, BE(G) 481, BE(G) 482; 1:1, complete. 043A500011

50 1 Transmission kit, BE(G) 481, BE(G) 482; 1:1.2, complete. 043A500010

50 1 Transmission kit, BE(G) 481, BE(G) 482; 1:1.4, complete. 043A500009

50 1 Transmission kit, BE(G) 481, BE(G) 482; 1:1.6, complete. 043A500008

50 1 Transmission kit, BE(G) 481, BE(G) 482; 1:1.8, complete. 043A500007

50 1 Transmission kit, BE(G) 481, BE(G) 482; 1:2.1, complete. 043A500006

50 1 Transmission kit, BE(G) 481, BE(G) 482; 1:2.3, complete. 043A500005

50 1 Transmission kit, BE(G) 481, BE(G) 482; 1:2.5, complete. 043A500004

50 1 Transmission kit, BE(G) 481, BE(G) 482; 1:2.8, complete. 043A500003

50 1 Transmission kit, BE 481, BE 482; 1:3.1, complete. 043A500002

50 1 Transmission kit, BE 481, BE 482; 1:3.4, complete. 043A500001

50 1 Transmission kit, BE(G) 485; 2.5:1, complete. 043A600017

50 1 Transmission kit, BE(G) 485; 2.1:1, complete. 043A600016

50 1 Transmission kit, BE(G) 485; 1.8:1, complete. 043A600015

50 1 Transmission kit, BE(G) 485; 1.6:1, complete. 043A600014

50 1 Transmission kit, BE(G) 485; 1.4:1, complete. 043A600013

50 1 Transmission kit, BE(G) 485; 1.2:1, complete. 043A600012

50 1 Transmission kit, BE(G) 485; 1:1, complete. 043A600011

50 1 Transmission kit, BE(G) 485; 1:1.2, complete. 043A600010

50 1 Transmission kit, BE(G) 485; 1:1.4, complete. 043A600009

50 1 Transmission kit, BE(G) 485; 1:1.6, complete. 043A600008

50 1 Transmission kit, BE(G) 485; 1:1.8, complete. 043A600007

50 1 Transmission kit, BE(G) 485; 1:2.1, complete. 043A600006

50 1 Transmission kit, BE(G) 485; 1:2.3, complete. 043A600005

50 1 Transmission kit, BE(G) 485; 1:2.5, complete. 043A600004

50 1 Transmission kit, BE(G) 485; 1:2.8, complete. 043A600003

50 1 Transmission kit, BE 485; 1:3.1, complete. 043A600002

50 1 Transmission kit, BE 485; 1:3.4, complete. 043A600001

51 1

Tooth belt, BE(G) 481, BE(G) 482 and BE(G) 485; 2.5:1, L = 600 mm.

Tooth belt, BE(G) 481, BE(G) 482 and BE(G) 485; 2.1:1, L = 600 mm.

Tooth belt, BE(G) 481, BE(G) 482 and BE(G) 485; 1.8:1, L = 620 mm.

Tooth belt, BE(G) 481, BE(G) 482 and BE(G) 485; 1.6:1, L = 620 mm.

Tooth belt, BE(G) 481, BE(G) 482 and BE(G) 485; 1.4:1, L = 660 mm.

422A000001

422A000002

422A000003

Pos. Qty Description Part no.

51 1

Tooth belt, BE(G) 481, BE(G) 482 and BE(G) 485; 1.2:1, L = 545 mm.

Tooth belt, BE(G) 481, BE(G) 482 and BE(G) 485; 1:1, L = 600 mm.

Tooth belt, BE(G) 481, BE(G) 482 and BE(G) 485; 1:1.2, L = 545 mm.

Tooth belt, BE(G) 481, BE(G) 482 and BE(G) 485; 1:1.4, L = 660 mm.

Tooth belt, BE(G) 481, BE(G) 482 and BE(G) 485; 1:1.6, L = 620 mm.

Tooth belt, BE(G) 481, BE(G) 482 and BE(G) 485; 1:1.8, L = 620 mm.

Tooth belt, BE(G) 481, BE(G) 482 and BE(G) 485; 1:2.1, L = 600 mm.

Tooth belt, BE(G) 481, BE(G) 482 and BE(G) 485; 1:2.3, L = 620 mm.

Tooth belt, BE(G) 481, BE(G) 482 and BE(G) 485; 1:2.5, L = 660 mm.

Tooth belt, BE(G) 481, BE(G) 482 and BE(G) 485; 1:2.8, L = 660 mm.

Tooth belt, BE 481, BE 482 and BE 485; 1:3.1, L = 620 mm.

Tooth belt, BE 481, BE 482 and BE 485; 1:3.4, L = 660 mm.

422A000007

422A000001

422A000007

422A000003

422A000002

422A000001

422A000002

422A000003

422A000002

422A000003

52 1 Pulley, Z = 20, for BE(G) 481/482, 2.5:1. 043V400386

52 1 Pulley, Z = 20, for BE(G) 485, 2.5:1. 043V400374

52 1 Pulley, Z = 24, for BE(G) 481/482, 1.2:1, 2.1:1. 043V400387

52 1 Pulley, Z = 24, for BE(G) 485, 1.2:1. 043V400375

52 1 Pulley, Z = 24, for BE(G) 485, 2.1:1. 043V400375

52 1 Pulley, Z = 28, for BE(G) 481/482, 1.8:1, 1:1.2. 043V400388

52 1 Pulley, Z = 28, for BE(G) 485, 1.8:1. 043V400376

52 1 Pulley, Z = 28, for BE(G) 485, 1:1.2. 043V400376

52 1 Pulley, Z = 31, for BE(G) 481/482, 1.6:1. 043V400389

52 1 Pulley, Z = 31, for BE(G) 485, 1.6:1. 043V400377

52 1 Pulley, Z = 37, for BE(G) 481/482, 1.4:1, 1:1. 043V400390

52 1 Pulley, Z = 37, for BE(G) 485, 1.4:1, 1:1. 043V400378

52 1 Pulley, Z = 50, for BE(G) 481/482, 1:1.4, 1:1.6, 1:1.8, 1:2.1. 043V400391

52 1 Pulley, Z = 50, for BE(G) 485, 1:1.4, 1:1.6, 1:1.8, 1:2.1. 043V400379

52 1 Pulley, Z = 55, for BE(G) 481/482, 1:2.3, 1:2.8. 043V400392

52 1 Pulley, Z = 55, for BE(G) 485, 1:2.3, 1:2.8. 043V400380

52 1 Pulley, Z = 61, for BE 481/482, 1:2.5, 1:3.1. 043V400393

52 1 Pulley, Z = 67, for BE 481/482, 1:3.4. 043V400394

52 1 Pulley, Z = 61, for BE(G) 485, 1:2.5, 1:3.1. 043V400381

52 1 Pulley, Z = 67, for BE 485, 1:3.4. 043V400382

53 1 Pulley, Z = 20, for BE(G) 481/482/485, 1:2.8, 1:3.1, 1:3.4. 043V400374

53 1

Pulley, Z = 24, for BE(G) 481/482/485, 1:1.2, 1:2.1, 1:2.3, 1:2.5.

043V400375

53 1 Pulley, Z = 28, for BE(G) 481/482/485, 1.2:1, 1:1.8. 043V400376

53 1 Pulley, Z = 31, for BE(G) 481/482/485, 1:1.6. 043V400377

53 1 Pulley, Z = 37, for BE(G) 481/482/485, 1:1, 1:1.4. 043V400378

53 1

Pulley, Z = 50, for BE(G) 481/482/485, 1.4:1, 1.6:1, 1.8:1, 2.1:1, 2.5:1.

043V400379

54 1 Spacer 043V400353

55 1 Washer 043V400632

56 1 Screw, MC6S 5x25 FZB, for BE 481 and BE 482. 411A121008

56 1 Screw, MC6S 6x20 FZB, for BE 485. 411A122043

Pos. Qty Description Part no.

58 1 Tension roll, complete. 043R000008

Miscellaneous:

1 Holder for adjustable adaptor TR 20x2. Automotive shank. 040J000008

1 Key Chuck JK2 6A-2A, Ø 0 – 13,0 mm (0 – 1/2''). 040J000107

1 Chuck Key for above key chuck. 041J004073

1 Drill Chuck JK2, Ø 1,0 – 10,0 mm (.04 – 3/8''). 040J000115

1 Drill Chuck JK2, Ø 1,0 – 13,0 mm (.04 – 1/2''). 040J000116

1 Drill Chuck JK2, Ø 3,0 – 16,0 mm (.12 – 5/8''). 040J000117

1 Collet ER32, Ø2 – 20 mm (.079 - .787 In). On request. 043J032XXX

1 Wrench for Collet Chuck Nut , ER32. 043J000002

1 Spanner, 32 mm, for ER32 collet chuck. 043J000003

1 Collet Chuck ER20/JT2, Ø2 – 15 mm (.08 – 9/16'') 040J000123

1 Collet ER20, Ø2 – 15 mm (.08 – 9/16''). On request. 041J008XXX

1 Wrench for Collet Chuck Nut, ER20. 041J004084

1 Collet Chuck ER40/JT2, Ø21 – 30 mm (13/16 – 1 3/16'') 040J000110

1 Collet ER40, Ø21 – 30 mm (13/16 – 1 3/16''). On request. 041J010XXX

1 Wrench for Collet Chuck Nut, ER40. 040J000111

Tapping spindle, type GS 12E with 25 mm (1'') length compensation, JT2.

Tapping spindle, type GS 24E with 40 mm (1 1/2'') length compensation, JT2.

042J000034

042J000035

1 Taper shank Ø16 – B18 for the GS 24E on a BE 48 ER. 042J000047

1 Tapholder T12. Please, On request. State Ø and #. 042JXXXXXX

1 Torque stop for tapping device. 043J400608

1 Collet ER32-ET1, Ø4,5 – 12,5 mm. 043J032XXX

1 Throttle-check valve, 1/8'' 075F000902

Warranty conditions

The warranty period for the product is 4 000 000 cycles or 12 months after installation/commissioning or 18 months after delivery, which of these occurs first, and provided that the product installed/stored in a satisfactory manner and that the product is used in normal operation, the mounting/clamping and handling conditions. The warranty is not valid if unauthorized change/modification have been performed on the product and that this may make the product unsafe.

Environmental declaration

Unit, Type BE 481 , BE 482, BE 485 or BEG 481, BEG 482, BEG 485.

Housing : Aluminium Pinole : Brass Electric motor : Aluminium, steel and Copper. Other parts : Aluminium, brass and steel. Seals, Drive belt : Rubber, Rubber/steel Hydraulic oil : Oil. The unit contains a small amount of hydraulic oil.

Housing, pinole and other metallic parts : Dispose as metal waste; Aluminium, brass and steel. Electric motor : Dispose as electric waste. Seals, Drive belt : Dispose as combustable waste. Hydraulic oil : Dispose as hazardous waste.

We reserve the right for any eventual text, picture or technical data errors.

Subject to changes.

E2 Systems BE 481, BE 482, BE 485, BEG 485, BEG 481 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual