Palmgren BF 46VARIO, 9680166 Operating Manual

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Operating manual

Version 1.1.4

Mill Drill

Item no. 9680166

Version 1.1.4 dated 2015-3-30Page 2 Original operating instructions

BF46 Vario | BF46TCUS

Table of contents

1 Safety

1.1 Type plate.................................................................................................................................................5

1.2 Safety instructions (warning notes)...........................................................................................................6

1.2.1 Classification of hazards............... ... .. ... ... .................................................................................................6

1.2.2 Other pictograms......................................................................................................................................7

1.3 Proper use................................................................................................................................................8

1.4 Reasonably foreseeable misuses.............................................................................................................8

1.4.1 Avoiding misuses.............................................................. ... ... ..................................................................9

1.5 Possible dangers caused by the mill drill................................................................................................10

1.6 Qualification of personnel.......................................................................................................................10

1.6.1 Target group...........................................................................................................................................10

1.7 Operator positions ..................................................................................................................................11

1.8 Safety measures during operation..........................................................................................................11

1.9 Safety devices ........................................................................................................................................12

1.9.1 EMERGENCY STOP impact switch.......................................................................................................12

1.9.2 Lockable main switch................................................... .. .........................................................................13

1.9.3 Protective cover......................................................................................................................................13

1.9.4 Separating protective equipment................................... ... ......................................................................13

1.10 Safety check...........................................................................................................................................14

1.11 Personnel protective equipment .............................................................................................................14

1.12 For your own safety during operation..................................................................................................... 15

1.13 Disconnecting and securing the mill drill.................................................................................................15

1.14 Using lifting equipment ...........................................................................................................................15

1.15 Position of labels on the mill drill.................................................. ... ... .....................................................16

2 Technical data

2.1 Electrical connection...............................................................................................................................17

2.2 Drilling-milling capacity ...........................................................................................................................17

2.3 Spindle seat............................................................................................................................................17

2.4 Drill-Mill head................................... .. ................................................... ... ...............................................17

2.5 Cross table..............................................................................................................................................17

2.6 Working area ..........................................................................................................................................17

2.10 Emissions ...............................................................................................................................................18

2.7 Speeds....................................................................................................................................................18

2.8 Environmental conditions.................................... ... .................................................. ... ............................18

2.9 Operating material..................................................................................................................................18

3 Unpacking and connecting

3.1 Scope of delivery....................................................................................................................................19

3.2 Transport ................................................................................................................................................19

3.3 Storage...................................................................................................................................................20

3.4 Installation and assembly .......................................................................................................................20

3.4.1 Requirements regarding the installation site...........................................................................................20

3.4.2 Load suspension point.................................................................... ... ... ..................................................21

3.4.3 Assembly................................................................................................................................................21

3.5 Dimensions, installation plan BF46V......................................................................................................22

3.6 Dimensions, installation plan BF46TC....................................................................................................23

3.7 Installation plan of optional substructure ................................................................................................24

3.8 First commissioning................................................................................................................................25

3.8.1 Power supply..........................................................................................................................................25

3.8.2 Cleaning and lubricating.........................................................................................................................25

3.8.3 Filling in gear oil......................................................................................................................................26

3.8.4 Warming up the machine................. .. ... ..................................................................................................26

3.8.5 Compressed air supply on BF46TC........................................................................................................26

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BF46 Vario | BF46TC US

3.9 Optional accessories..............................................................................................................................27

4Operation

4.1 Control and indicating elements BF46V......................................... ... .....................................................28

4.1.1 Control panel..........................................................................................................................................29

4.2 Switching on the mill drill........................................................................................................................30

4.3 Switching off the mill drill........................................................................................................................30

4.4 Inserting a tool on BF46V.......................................................................................................................31

4.4.1 Installation..............................................................................................................................................31

4.4.2 Unfitting..................................................................................................................................................31

4.5 Threading ...............................................................................................................................................32

4.6 Control and indicating elements BF46TC...............................................................................................33

4.6.1 Control panel BF46TC............................................................................................................................34

4.7 Switching on the mill drill........................................................................................................................35

4.8 Switching off the mill drill........................................................................................................................36

4.9 Traveling the drilling milling head (Z-axis) upward respectively downward............................................36

4.9.1 Traveling the drill-mill head upward respectively downward by actuating the crank handle. ................. 36

4.10 Threading ...............................................................................................................................................37

4.10.1 Traveling the drill-mill head upward respectively downward using the control panel .............................37

4.11 Inserting a tool on BF46TC ....................................................................................................................37

4.11.1 Installation..............................................................................................................................................37

4.11.2 Unfitting..................................................................................................................................................38

4.12 Safety.....................................................................................................................................................40

4.13 Use of collet chucks ...............................................................................................................................40

4.14 Clamping the workpieces.......................................................................................................................40

4.15 Changing the speed range.....................................................................................................................40

4.16 Manual spindle sleeve feed with the fine feed........................................................................................41

4.17 Digital display for spindle sleeve travel ..................................................................................................41

17.1

Malfunctions...........................................................................................................................................42

4.18 Manual spindle sleeve feed with the spindle sleeve lever......................................................................43

4.19 Swivelling the drill-mill head................................................................. ..................................................43

4.20 Selecting the speed................................................................................................................................43

4.20.1 Standard values for cutting speeds........................................................................................................44

4.20.2 Standard values for speeds with HSS – Eco – twist drilling (U.S. unit)..................................................45

5 Maintenance

5.1 Safety.....................................................................................................................................................46

5.1.1 Preparation.............................................................................................................................................46

5.1.2 Restarting...............................................................................................................................................46

5.2 Inspection and maintenance ..................................................................................................................46

5.3 Repair .....................................................................................................................................................50

1 Spare parts

1.1 Milling head 1 - 3.................................................................................................................................... 51

1.2 Milling head BF 46 TC Vario ..................................................................................................................52

1.3 Milling head 2 - 3...................................................................................................................................53

1.4 Milling head 3 - 3.................................................................................................................................... 54

1.5 Milling head BF46TC..............................................................................................................................54

1.6 Column...................................................................................................................................................55

1.7 Column BF46TC.....................................................................................................................................56

1.8 Cross table 1 - 2.....................................................................................................................................57

1.9 Cross table 2 - 2.....................................................................................................................................58

1.10 Protection device....................................................................................................................................59

1.11 Machine stand (option)...........................................................................................................................60

1.11.1 Spare parts list .......................................................................................................................................61

1.12 Wiring diagram 1 of 2/ BF46, BF46TC...................................................................................................66

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BF46 Vario | BF46TCUS

1.13 Wiring diagram 2 of 2/ BF46TC..............................................................................................................67

1.13.1 Parts list electrical components BF46 Vario, BF46TC Vario ............................................................. .....68

1.14 Lubrication diagram................................................................................................................................69

1.14.1 Lubricating unit .......................................................................................................................................69

2 Malfunctions 3 Appendix

3.1 Copyright ................................................................................................................................................73

3.2 Terminology/Glossary.............................................................................................................................73

3.3 LIMITED WARRANTY ...........................................................................................................................74

Preface

Dear customer, Thank you very much for purchasing a product made by company. Company metal working machines offer a maximum of quality, technically company solutions and convince

by an outstanding price performance ratio. Continuous enhancements and product innovations guarantee state-of-the-art products and safety at any time.

Before commissioning the machine please thoroughly read these operating instructions and get familiar with the machine. Please also make sure that all persons operating the machine have read and understood the operating instructions beforehand. Keep these operating instructions in a safe place nearby the machine.

Information

The operating instructions include indications for safety-relevant and proper installation, operation and maintenance of the machine. The continuous observance of all notes included in this manual guarantee the safety of persons and of the machine.

The manual determines the intended use of the machine and includes all necessary information for its economic operation as well as its long service life.

In the paragraph "Maintenance" all maintenance works and functional tests are described which the operator must perform in regular intervals.

The illustration and information included in the present manual can possibly deviate from the current state of construction of your machine. Being the manufacturer we are continuously seeking for improvements and renewal of the products. Therefore, changes might be performed without prior notice. The illustrations of the machine may be different from the illustrations in these instructions with regard to a few details. However, this does not have any influence on the operability of the machine. Therefore, no claims may be derived from the indications and descriptions. Changes and errors are reserved!

Your suggestion with regard to these operating instructions are an important contribution to optimising our work which we offer to our customers. For any questions or suggestions for impro veme nt, please do not hesitate to contact us.

If you have any further questions after reading these operating instructions and you are not able to solve your problem with a help of these operating instructions, please contact your specialised dealer or

C.H.HANSON 2000 North Aurora Rd. Naperville,IL 60563 Call 800-827-3398

Version 1.1.4 dated 2015-3-30 Page 5Original operating instructions

BF46 Vario | BF46TC US

1 Safety

This part of the operating instructions

 explains the meaning and use of the warning references contained in the operating manual,  explains how to use the lathe properly,  highlights the dangers that might arise for you or others if these instructions are not obeyed,  tells you how to avoid dan g ers .

In addition to this operating manual please observe

 applicable laws and regulations,  legal regulations for accident prevention,  the prohibition, warning and mandatory signs as well as the warning notes on the mill drill.

Consult OSHA, state and local regulations in order to determine compliance, danger and risks to the operator.

Always keep this documentation close to the mill drill.

If you would like to order another operating manual for your machine, please indicate the serial number of your machine. Please find the serial number on the type plate.

1.1 Type plate

INFORMATION

If you are unable to solve a problem using the se operating instructions, please contact us for advice: Exclusive USA Agent

C.H.HANSON

2000 North Aurora Rd.

Naperville,IL 60563

Call 800-827-3398

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BF46 Vario | BF46TCUS

1.2 Safety instructions (warning notes)

1.2.1 Classification of hazards

We classify the safety warnings into various levels. The table below gives an overview of the classification of symbols (ideogram) and the warning signs for each specific danger and its (possible) consequences.

Ideogram Warning alert Definition / consequence

DANGER!

Threatening danger that will cause serious injury or death to people.

WARNING!

A danger that might cause severe injury to the staff or can lead to death.

CAUTION!

Danger or unsafe procedure that might cause injury to people or damage to property.

ATTENTION!

Situation that could cause damage to the mill drill and products and other types of damage.

No risk of injury to people.

INFORMATION

Application tips and other important or useful information and notes. No dangerous or harmful consequences for people or objects.

In case of specific dangers, we replace the pictogram by

general danger by a warning of injury of hands, hazardous electri-

cal voltage,

rotating parts.

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1.2.2 Other pictograms

Warning of danger of

slipping!

Warning risk of stumbling! Warning hot surface! Warning biological hazard!

Warning of automatic

start-up!

Warning tilting danger! Warning of suspended

loads!

Caution, danger of

explosive substances!

Activation forbidden! Read the operating

instructions before

commissioning!

Disconnect the mains plug!

Use protective glasses! Use protective gloves! Use protective boots! Use protective suit!

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1.3 Proper use

WARNING! In the event of improper use, the mill drill

 will endanger personnel,  the mill drill and other material property of the operating company will be endan-

gered,

 the correct function of the mill drill may be affected.

The mill drill is designed and manufactured to

be used for milling and drilling cold metals or other non-flammable materials or materials that do not constitute a health hazard by using commercial milling and drilling tools.

The mill drill must only be installed and operated in a dry and well-ventilated place. If the mill drill is used in any way other than described above, modified without the approval of

the company then the mill drill is being used improperly. We will not be held liable for any damages resulting from any operation which is not in accord-

ance with the intended use. We would like to stress that any modifications to the construction, or technical or technological

modifications that have not been authorized will also render the warranty null and void. It is also part of proper use that

 the limits of the mill drill are observed,  the operating manual is observed,  the inspection and maintenance instructions are observed.

 "Technical data“ on page 17

WARNING! Heaviest injuries through improper use.

It is forbidden to make any modifications or alternations to the operation values of the mill drill. They could endanger the staff and cause damage to the mill drill.

ATTENTION! If the mill drill is not used as intended or if the safety directives or the operating

instructions are ignored the liability of the manufacturer for any damages to persons or objects resulting hereof is excluded and the claim under guarantee is becoming null and void!

1.4 Reasonably foreseeable misuses

Any other use as the one determined under the "Intended use" or any use beyond the described use shall be deemed as not in conformity and is forbidden.

Any other use has to be discussed with the manufa cturer. It is only allowed to process metal, cold and non-inflammable materials with the mill drill. In order to avoid misuses it is necessary to read and understand the operating instructions

before the first commissioning. The operators must be qualified.

Use ear protection! Only switch in standstill! Protect the environment! Contact address

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BF46 Vario | BF46TC US

1.4.1 Avoiding misuses

 Use of suitable cutting tools.  Adapting the speed adjustment and feed to the material and workpiece.  Clamp workpieces firmly and vibration-free.

ATTENTION! The workpiece is always to be fixed by a machine vice, jaw chuck or by another

appropriate clamping tool such as for the clamping claws. WARNING!

Risk of injury caused by workpieces flying off.

Clamp the workpiece in the machine vice. Make sure that the workpiece is firmly clamped in the machine vice resp. that the machine vice is firmly clamped on the machine table.

 Use cooling and lubricating agents to increase the durability of the tool and to improve the

surface quality.

 Clamp the cutting tools and workpieces on clean clamping surfaces.  Sufficiently lubricate the machine.  Correctly adjust the bearing clearance and the guidings.

It is recommended:

 Insert the drill in a way that it is exactly positioned between the three clamping jaws of the

quick action chuck.

 Clamp and mills by means of the collet chuck and the corresponding collets.  Clamp end face mills by means of shell end mill arbors.

When drilling make sure that

 the suitable speed is set depending on the diameter of the drill,  the pressure must only be such that the drill can cut without load  in case of too strong pressure the drill will get worn early or even might break resp. get

jammed in the hole. If the drill gets jammed immediately stop the main motor by pressing the emergency stop button,

 for hard materials, e.g. steel, use commercial cooling / lubricating agents,  generally always drive the turning spindle out of the workpiece.

ATTENTION! Do not use the quick action drill chuck for milling tools. Never clamp a milling cutter into

the quick action drill chuck. Use a collet chuck and the corresponding collets for the end mill.

When milling make sure that

 the corresponding cutting speed is selected,  for workpieces with normal strength values, e.g. steel 18-22 m/min,  for workpieces with high strength values 10-14 m/min,  the pressure is selected in a way that the cutting speed remains constant,

for hard materials commercial cooling / lubricating agents are used.

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BF46 Vario | BF46TCUS

1.5 Possible dangers caused by the mill drill

The mill drill is state-of-the-art. Nevertheless, there is a residual risk as the mill drill operates with

 at high speeds,  with rotating parts and tools,  with electrical voltages and currents.

We have used construction resources and safety techniques to minimize the health risk to persons resulting from these hazards.

If the mill drill is used and maintained by personnel who are not duly qualified, there may be a risk resulting from incorrect or unsuitable maintenance of the mill drill.

INFORMATION

Everyone involved in the assembly, commission i ng , ope ra tio n an d main te na nce must

 be duly qualified,  strictly follow these operating instructions.

Always disconnect the mill drill from the electrical power supply when performing cleaning or maintenance works.

WARNING! The mill drill may only be used with functional safety devices.

Disconnect the mill drill immediately, whenever you detect a failure in the safety devices or when they are not fitted!

All additional devices installed by the operator have to be equipped with the prescribed safety devices.

This is your responsibility being the operating company!

 "Safety devices“ on page 12

1.6 Qualification of personnel

1.6.1 Target group

This manual is addressed to

 the operating comp anie s,  the users,  the staff for maintena nc e wo rks.

Therefore, the warning notes refer to both, operation and maintenance staff of the mill drill. Disconnect the mill drill always from the electrical power supply. This will prevent it from being

used by unauthorized staff. The qualifications of the staff for the different tasks are mentioned below:

Operator

The operator is instructed by the operating company about the assigned tasks and possible risks in case of improper behaviour. Any tasks which need to be performed beyond the operation in the standard mode must only be performed by the operator if it is indicated in these instructions and if the operating company expressively commissioned the operator.

Electrical specialist

Due to his professional training, knowledge and experience as well as his knowledge of respective standards and regulations the electrical specialist is able to perform works on the electrical system and to recognise and avoid any possible dangers himself.

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BF46 Vario | BF46TC US

The electrical specialist is specially trained for the working environment in which he is working and knows the relevant standards and regulations.

Specialist staff

Due to their professional training, knowledge and experience as well as their knowledge of relevant regulations the specialist staff is able to perform the assigned tasks and to recognise and avoid any possible dangers themselves.

Instructed persons

Instructed persons were instructed by the operating company about the assigned tasks and any possible risks in case of improper behaviour.

INFORMATION

Everyone involved in the assembly, commissioning, operation and maintenance must

 be duly qualified,  strictly follow these operating instructions.

In the event of improper use

 there may be a risk to the staff,  there may be a risk to the mill drill and other material values,  the correct function of the mill drill may be affected.

1.7 Operator positions

The operator’s position is in front of the mill drill.

Fig.1-1: Operator positions

1.8 Safety measures during operation

CAUTION! Risk due to inhaling of health hazardous dusts and mist.

Dependent on the material which need to be processed and the used auxiliaries dusts and mist may be caused which might impair you health.

Make sure that the generated health hazardous dusts and mist are safely sucked off at the point of origin and is dissipated or filtered from the working area. To do so, use a suitable extraction unit.

CAUTION! Risk of fire and explosion by using flammable materials or cooling lubricants.

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Before processing inflammable materials (e.g. aluminium, magnesium) or using inflammable auxiliary materials (e.g. spirit) it is necessary to take additional preventive measures in order to safely avoid health risks.

1.9 Safety devices

Use the mill drill only with properly functioning safety devices. Stop the mill drill immediately if there is a failure on the safety device or if it is not functioning for

any reason. It is your responsibility! If a safety device has been activated or has failed, the mill drill must only be used if you

 have removed the cause of the failure,  have verified that there is no danger resulting for the staff or objects.

WARNING! If you bypass, remove or deactivate a safety device in any other way, you are

endangering yourself and other staff working with the mill drill. The possible consequences are

 injuries due to components or parts of components flying off at high speed,  contact with rotating parts,  fatal electroc ut io n.

The mill drill includes the following safety devices:

 an EMERGENY-STOP button,  a protective cover on the drill / mill head.  a separating protective device on the milling spindle,

WARNING! The separating protective equipment which is made available and delivered together

with the machine is designed to reduce the risk of workpieces or fractions of them which being expelled, but not to remove them completely. Always work carefully and observe the limit values of your chipping process.

1.9.1 EMERGENCY STOP impact switch

The EMERGENCY STOP push button switches off the mill drill.

Fig.1-2: EMERGENCY STOP impact switch

ATTENTION! The EMERGENCY-STOP push button stops the machine the moment it is activated.

Activate the emergency stop impact switch only in case of danger! If this push button is actuated in order to switch off the mill drill in the standard operation the tool or workpiece might get damaged.

After having actuated the EMERGENCY STOP, turn the knob of the particular push but ton to the right in order to restart the machine.

EMERGENCY-

STOP

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BF46 Vario | BF46TC US

1.9.2 Lockable main switch

In the position " 0 " the lockable main switch can be secured against accidental or non-authorized switching-on by means of a padlock.

When the main switch is switched-off, the current supply is interrupted.

Except for the areas marked by the pictogram in the margin.

Fig.1-3: Main switch

WARNING! Dangerous voltage even if the main switch is switched-off. In the areas marked by the

ideogram in the margin, there might be voltage, even if the mai n sw it ch is sw it ch e d off .

1.9.3 Protective cover

The drilling / milling head is equipped with a protective cover.

WARNING! Only remove the protective cover

when the mains plug of the mill drill is disconnected.

Fig.1-4: Protective cover

1.9.4 Separating protective equipment

Adjust the protective equipment to the correct height before you start working. To do so, detach the clamping screw, adjust the required height and re-tighten the clamping screw.

A switch is integrated in the fixture of the spindle protection which monitors that the cover is closed.

INFORMATION

You cannot start the machine if the spindle protection is not closed.

Fig.1-5: Separating protective equipment

Main switch

Protective

cover

Clamping screw

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1.10 Safety check

Check the mill drill in regular intervals. Check all safety devices

 before each operation,  once a week (with the machine in operation),  after every maintenance and repair work.

1.11 Personnel protective equipment

For certain work personal protective equipment is required. Protect your face and your eyes: Wear a safety helmet with facial protection when performing

works where your face and eyes are exposed to hazards.

Use protective gloves when handling pieces with sharp edges.

Use safety shoes when you assemble, disassemble or transport heavy components.

Use ear protection if the noise level (emission) in the workplace exceeds 80 dB (A). Before starting work make sure that the prescribed personnel protective equipment is available

at the working place.

CAUTION! Dirty or contaminated personnel protective equipment can cause diseases. Clean it each

time after use and once a week.

General check Equipment Check OK

Protective covers Mounted, firmly bolted and not damaged Signs,

Markings

Installed and legible

Functional check Equipment Check OK

EMERGENCY STOP impact switch

When the EMERGENCY STOP push button is activated, the mill drill must switch off. Make sure that it is only possible to restart the machine if the EMERGENCY STOP push button is unlocked and the ON switch was activated.

Separating safety device around the drilling and milling spindle

The mill drill may switch on only when the safety device is closed.

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1.12 For your own safety during operation

WARNING! Before activating the mill drill assure yourself that this will neither endanger other

persons nor cause damage to equipment.

Avoid any unsafe working practices: Make sure that nobody is endangered by your work.

 The instructions mentioned in these operating instructions have to be strictly observed dur-

ing assembly, operation, maintenance and repair.

 Wear safety goggles.  Switch off the mill drill before measuring the workpiece.  Do not work on the mill drill, if your concentration is reduced, for example, because you are

taking medication.

 Stay on the mill drill until the working spindle has come to a complete standstill.  Use the prescribed personnel protective equipment. Make sure to wear a well-fitting work

suit and, if necessary, a hairnet.

 Do not use protective gloves during drilling or milling work.  Disconnect the shock-proof plug from the outlet before replacing the tool.  Use appropriate auxiliary materials to remove drilling and milling chips.  Make sure that nobody is endangered by your work.  Safely and firmly clamp the workpiece before switching on the mill drill.

We specially point out the specific dangers when working with and on the mill drill.

1.13 Disconnecting and securing the mill drill

Switch off the mill drill with the main switch before starting any maintenance and repair works.

1.14 Using lifting equipment

WARNING! The use of unstable lifting and load suspension gear that might break under load can

cause severe injuries or even death. Check that the lifting equipment and load-suspension gears are of sufficient load

capacity and are in perfect condition. Observe the accident prevention regulations issued by your Employers Liability

Insurance Association or other competent supervisory authority, responsible for your company.

Fasten the loads properly. Never walk under suspended loads!

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1.15 Position of labels on the mill drill

Fig.1-6: BF46 Vario | BF46TC

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BF46 Vario | BF46TC US

2 Technical data

The following information are the dimensions and indications of weight and the manufacturer‘s approved machine data.

2.1 Electrical connection

BF46 Vario BF46TC

Motor 3 HP, 230V, 1Ph, 60Hz

2.2 Drilling-milling capacity

BF46 Vario BF46TC

Drilling capacity in steel 1.1" max. diam./28 mm

Drilling capacity in cast 1.2" max. diam./30 mm

Milling capacity end mill 1.3" max. diam./32 mm

Milling capacity milling head

Ø 3.15" max. diam./80 mm

Swing 10.24"/ 260mm

2.3 Spindle seat

BF46 Vario BF46TC

Spindle seat R8

optional

ISO 40 (DIN 2080, DIN 69871) MT4

Extraction rod (Draw-in rod) 7/16"

optional M16 (ISO 40)

Quill travel 4.5"/ 115 mm

2.4 Drill-Mill head

BF46 Vario BF46TC

Swivelling + / - 45°

Gear stages 3

Travel of Z axis 21.3"/ 541 mm

2.5 Cross table

BF46 Vario BF46TC

Table length 33.5"/ 850 mm

Table width 9.5"/ 240 mm Travel of Y axis 10.2"/ 260 mm Travel of X axis 20.5"/ 520 mm

T - slot size / number / distance [mm] 18 mm slots, three

Max. load [lbs] 385

2.6 Working area

BF46 Vario BF46TC

Height 86.6"/ 2200 mm

Depth 78.7"/ 2000 mm

Width 102.4"/ 2600 mm

Total weight 1058 lbs./ 480 Kg

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2.10 Emissions

The generation of noise emitted by the mill drill is 80 dB(A). If the mill drill is installed in an area where various machines are in operation, the noise exposure (immission) on the operator of the mill drill at the working place may exceed 80dB(A).

INFORMATION

This numerical value was measured on a new machine under proper operating conditions. Depending on the age respectively on the wear of the machine it is possible that the noise behaviour of the machine changes.

Furthermore, the factor of the noise emission is also depending on manufacturing influencing factors, e.g. speed, material and clamping conditions.

INFORMATION

The mentioned numerical value is the emission level and not necessarily a safe working level. Though there is a dependency between the degree of the noise emission and the degree of the

noise disturbance it is not possible to us e it reliably to determine if further precaution measures are required or not.

The following factors influence the actual degree of the noise exposure of the operator:

 Characteristics of the working area, e.g. size or damping behaviour,  Other noise sources, e.g. the number of machines,  Other processes taking place in the proximity and the period of time during which the oper-

ator is exposed to the noise.

Furthermore, it is possible that the admissible exposure level might be different fr om country to country due to national regulations. This information about the noise emission shall allow the operator of the machine to more easily evaluate the endangering and risks.

CAUTION! Depending on the overall noise exposure and the basic limit values the machine

operators must wear an appropriate hearing protection. We generally recommend to use a noise protection and a hearing protection.

2.7 Speeds

BF46 Vario BF46TC

Gear stage slow [min-1]115 - 720 RPM

Gear stage average [min-1] 324 - 1680 RPM

Gear stage rapid [min

-1

] 708 - 3100 RPM

2.8 Environmental conditions

BF46 Vario BF46TC

Temperature 40 - 95 °F / 5 - 35 °C

Humidity 25 - 80%

2.9 Operating material

BF46 Vario BF46TC

Gear Oil quantity 1-3/4 Qts. (1.7 L)

628 Mobil (Vis. 100/150) or a corresponding oil,

see also

 "Lubricant“ on page 71

Bare steel parts Mobilux EP 004, acid-free oil, e.g. weapon oil, motor oil

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3 Unpacking and connecting

INFORMATION

The mill drill is delivered pre-assembled.

3.1 Scope of delivery

Check immediately upon delivery of the mill drill if there are any transport damages or loosened fastening screws.

Compare the scope of delivery with the packing list.

3.2 Transport

WARNING! Severe or fatal injuries may occur if parts of the machine tumble or fall down from the

forklift truck or from the transport ve hicle. Follow the instructions and information on the transport case.

WARNING! The use of unstable lifting and load suspension gear that might break under load can

cause severe injuries or even death. Check that the lifting and load suspension gear has sufficient load capacity and that it is in perfect condition.

Observe the accident prevention regulations issued by your Employers Liability Insurance Association or other competent supervisory authority, responsible for your company.

Fasten the loads properly. Never walk under suspended loads!

 Centres of gravity

 Load suspension points

(Marking of the positions for the load suspension gear)

 Prescribed transportation position

(Marking of the top surface)

 Means of transport to be used  Weights

Version 1.1.4 dated 2015-3-30Page 20 Original operating instructions

BF46 Vario | BF46TCUS

3.3 Storage

ATTENTION! In case of wrong and improper storage electrical and mechanical machine components

might get damaged and destroyed. Store packed and unpacked parts only under the intended environmental conditions. Follow the instructions and information on the transport case.

Consult company if the machine and accessories are stored for more than three months or are stored under different environmental conditions than those given here.

3.4 Installation and assembly

3.4.1 Requirements regarding the installation site

Organize the working area around the drilling machine according to the local safety regulations.

INFORMATION

order to attain good functionality and a high processing accuracy as well as a long durability

of the machine the installation site should fulfil certain criteria.

Please observe the following points:

 The device must only be installed and operated in a dry and well-ventilated place.  Avoid places nearby machines generating chips or dust.  The installation site must be free from vibrations also at a distance of presses, planing

machines, etc.

 The substructure must be suitable for the mill drill. Also make sure that the floor has suffi-

cient load bearing capacity and is level.

 The substructure must be prepared in a way that possibly used coolant cannot penetrate

into the floor.

 Any parts sticking out such as stops, handles, etc. have to be secured by measures taken

by the customer if necessary in order to avoid endangerment of persons.

 Fragile goods

(Goods require careful handling)

 Protect against moisture and humid environment

 "Environmental conditions“ on page 18.

 Prescribed position of the packing case

(Marking of the top surface - arrows pointing to the top)

 Maximum stacking height

Example: not stackable - do not stack a second packing case on top of the first one.

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BF46 Vario | BF46TC US



Provide sufficient space for the staff preparing and operating the machine and transporting the material.

 Also consider that the machine is accessible for setting and maintenance works.  Provide for sufficient illumination (Minimum value: 500 lux, measured at the tool tip). At little

intensity of illumination an additional illumination has to be ensured e.g. by means of a separate workplace lamp.

INFORMATION

The mains plug of the mill drill must be freely accessible.

3.4.2 Load suspension point

WARNING! Danger of crushing and overturning. Proceed carefully when lifting, installing and

assembling the machine.

 Secure the load-suspension device around the drill-mill head. Use a lifting sling for this pur-

pose.

 Firmly clamp all clamping levers on the mill drill before lifting the mill drill.  Make sure that the load attachment does not cause damage to components or paint.

3.4.3 Assembly

 Check if the underground of the mill drill is level using a spirit level.  Check if the underground is sufficiently stable and rigid.

The total weight amounts to 1058 lbs./ 480 Kg.

ATTENTION! Insufficient rigidity of the foundation leads to the superposition of

the vibrations of the mill drill and of the underground (natural frequency of components). Critical speeds and moves in the axis with displeasing vibrations are rapidly achieved in case of insufficient rigidity of the whole system and will lead to bad milling results.

 Place the mill drill on the provided underground.  Fix the mill drill in the provided through-holes on the machine foot.

The attachment points are marked by arrows on the machine foot.

WARNING! The condition of the underground and the fixing type of the machine foot to the

underground must be in a way that it can bear the loads of the mill drill. The underground must be level. Check if the underground of the mill drill is level using a spirit level.

Fix the foot of the mill drill to the substructure with the provided through-holes. We recommend you to use shear connector cartridges resp. heavy-duty anchors.

Version 1.1.4 dated 2015-3-30Page 22 Original operating instructions

BF46 Vario | BF46TCUS

3.5 Dimensions, installation plan BF46V

A-A

2.165" (55mm)

37.4" (950mm)

10.63" (270mm)

)

14.96" (380mm)

10.236" (260mm)

33.465" (850mm)

47.637" (1210mm)

15.354" (390mm)

)

(

)

18.897" (480mm)

Centre of gravity

17.322" (440mm)

)

(

)

Version 1.1.4 dated 2015-3-30 Page 23Original operating instructions

BF46 Vario | BF46TC US

3.6 Dimensions, installation plan BF46TC

A-A

)

10.236" (260mm)

14.96" (380mm)

9.448" (240mm)

33.464" (850mm)

47.637" (1210mm)

(

)

15.354" (390mm)

17.323" (440mm)

)

17.72" (450mm)

10.63" (270mm)

Centre of gravity

38.97" (990mm)

Version 1.1.4 dated 2015-3-30Page 24 Original operating instructions

BF46 Vario | BF46TCUS

3.7 Installation plan of optional substructure

A-A

(

)

21.653" (550mm)

(

)

29.527" (750mm)

)

(

)

(

)

15.354" (390mm)

9.842" (250mm)

(

)

27.165" (690mm)

(

)

Version 1.1.4 dated 2015-3-30 Page 25Original operating instructions

BF46 Vario | BF46TC US

3.8 First commissioning

ATTENTION! Before commissioning the machine check all screws, fixtures resp. safety devices and

tighten up the screws if necessary! WARNING!

Risk by using improper tool holders or operating them at inadmissible speeds. Only use the tool holders (e.g. drill chuck) which were delivered with the machine or which are offered as optional equipment by company. Only use tool holders in the intended admissible speed range.

Tool holders may only be modified in compliance with the recommendation of company or of the manufacturer of the clamping devices.

WARNING! When first commissioning the mill drill by inexperienced staff you endanger people and

the machine. We do not take any liability for damages caused by incorrectly performed commission-

ing.

 "Qualification of personnel“ on page 10

3.8.1 Power supply

 Connect the electrical supply cable.

Check the fusing (fuse) of your electrical supp ly according to the technical instruct ions regarding the total connected power of the mill drill.

3.8.2 Cleaning and lubricating

 Remove the anti-corrosive agents on the mill drill which had been applied for transportation

and storage. Therefore, we recommend you to use paraffin.

 Do not use any solvents, cellulose thinner or any other cleaning agents which might affect

the coating of the mill drill when cleaning the machine. Observe the indications and notes of the manufacturer for cleaning agents.

 Oil all blank machine parts using an acid-free lubricating oil.  Lubricate the mill drill according to the lubricating plan.

 "Inspection and maintenance“ on page 46  Check if all spindles are running smoothly. The spindle nuts are re-adjustable.  Disassemble the V-ledges of the cross table and clean the ledges from the anti-corrosive

agent.

 "V-ledges“ on page 49

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BF46 Vario | BF46TCUS

3.8.3 Filling in gear oil

The mill drill is delivered without oil filling. Fill in gear lubricant oil into the drill-mill head and the central lubrication unit.

 "Oil change“ on page 48

3.8.4 Warming up the machine

ATTENTION! If the mill drill and in particular the milling spind le is immediately operated at maximum

load when it is cold it may result in damages.

If the machine is cold such as e.g. dir ectly after having transported the machine it should be warmed up at a spindle speed of only 500 rpm for the first 30 minutes.

3.8.5 Compressed air supply on BF46TC

 Connect the compressed air supply

with at least 87 psi (6 bars) to the quick-action coupling of the compressed air maintenance unit.

ATTENTION! In order to ensure a failure-free

operation of the machine it is necessary that the required air pressure is continuously applied on the machine at constant quality.

Fig.3-1: Compressed air supply

Compressed air

service unit

Version 1.1.4 dated 2015-3-30 Page 27Original operating instructions

BF46 Vario | BF46TC US

3.9 Optional accessories

Description Item No

Machine stand

Dimensions

 "Installation plan of optional substructure“

on page 24

335 3005

Vice 5" Precision Modular 3355553

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BF46 Vario | BF46TCUS

4 Operation

4.1 Control and indicating elements BF46V

Img.4-1: BF46 Vario | BF46TC

Pos. Designation Pos. Designation

1 Cover of draw-in rod 2 Control panel 3 Digital display fine crossfeed of spindle

sleeve

4 Spindle protection

5 Crank for height adjustment of the drill-mill

head

6 Selector switch for reduction stage

7 Star grip for spindle sleeve feed 8 Activation of the fine adjustment 9 Fine adjustment of spindle sleeve 10 Central lubrication

Version 1.1.4 dated 2015-3-30 Page 29Original operating instructions

BF46 Vario | BF46TC US

4.1.1 Control panel

Img.4-2: Control panel

Selection switch for operating mode

With the selector switch the operating mode „automatic, threading or right-hand respectively left-hand run“ is being selected.

Operation mode automatic

In the automatic mode the engine starts up according to a predefined path over the drilling depth limit of the spindle sleeve and stop at the end position. This way for, the push button Start and Stop does not have to be actuated for repetitive drilling tasks.

Pos. Designation Pos. Designation

20 Speed control 21 Digital display speed 22 EMERGENCY-STOP 23 Selection switch operating mode

 Automatic  Threading  turning direction

24 Push button spindle rotation "ON" 25 Push button spindle rotation "OFF" 26 Main switch 6 Selector switch for reduction stage 3 Digital display fine crossfeed of spindle

sleeve

9 Fine adjustment of spind le sle ev e

Version 1.1.4 dated 2015-3-30Page 30 Original operating instructions

BF46 Vario | BF46TCUS

Operation mode thread cutting

In the thread cutting mode the engine automatically starts up according to a predefined path over the drilling depth stop and automatically changes the turning direction as soon as the predefined depth had been achieved. The screw-tap is drawn out of the workpiece.

Rotation direction switch

Standard operation, selection left-handed or right-ha nded rotation.

Potentiometer

Speed setting "VARIO"

Push button ON

The push button "ON"

switches on the rotation of the spindle.

Push button OFF

The push button "OFF“

switches off the rotation of the spindle.

Main switch

Interrupts or connects the power supply.

4.2 Switching on the mill drill

 Switch on the main switch.  Close the protective equipment.  Select the operating mode.  Select the gear level.  Set the potentiometer to the lowest speed.  Actuate push button "Start".  Set the required speed on the potentiometer.

ATTENTION! Wait until the mill drill has come to a complete halt before changing the rotation

direction using the rotation direction switch. INFORMATION

At a cold mill drill it is possible that with switchin g on the machine an overload of the drive occur.

Therefore, allow the mill drill at low speeds depending on environmental conditions to warm up for 10 to 20 minutes before you go to maximum speed.

Also with a quick on and off, this overload occur. Therefore wait for about 3 seconds before you switch on the mill drill again, the capacitors in the controller must first discharged.

4.3 Switching off the mill drill

 Press the push button spindle rotation "OFF". For a long-term standstill of the mill drill

switch it off at the main switch.

Version 1.1.4 dated 2015-3-30 Page 31Original operating instructions

BF46 Vario | BF46TC US

4.4 Inserting a tool on BF46V

4.4.1 Installation

CAUTION! When milling operations are performed the cone seat must always be fixed to the draw-

in rod. All cone connections with the taper bore of the work spindle without using the draw-in rod is not allowed for milling operations. The cone connection should be released by the lateral pressure. Injuries may be caused by parts flying off.

The milling head is equipped with a draw-in rod M16.

 Remove the cap.  Clean the seat in the spindle / quill.  Clean the taper of your tool.  Insert the tool in the spindle / quill.

Img.4-3: Drilling and milling head

 Screw the draw-in bar in the tool.  Tighten the tool with the draw-in rod

and hold the spindle on the counter

bearing by means of a wrench.

Img.4-4: Drilling-milling head without cap

4.4.2 Unfitting

 Hold the spindle counter bearing with a wrench and loosen the draw-in rod. Continue turn-

ing the draw -in rod, so that the tool is squeezed out from the conical collet.

ATTENTION! When using an optional MT4 spindle.

When installing a cold morse taper into a heated-up machine those MT seats tend to shrink on the morse taper contrary to the quick-releaser tapers.

Cap

Draw-in rod

Steady/

counter bearing

Version 1.1.4 dated 2015-3-30Page 32 Original operating instructions

BF46 Vario | BF46TCUS

4.5 Threading

Img.4-5: Operation mode thread cutting

 Set the selection switch mode (23) to "threading" or "automatic".  Set the depth stop (26) to the desired depth.  Select the smallest speed.  Close spindle protection system.  Start the rotation of spindle (24).  Move the sleeve downward with the sleeve lever until the machine tap cams in the work-

piece.

The machine tap turns into the workpiece. As soon as the preset depth is attained, the spindle reverses the direction of rotation at the switch point (28). The machine tap turns out of the workpiece. When the spindle sleeve is completely entered up to the switch point (27) in operation mode "automatic" the rotation of the spindle is stopped. Then it is possible to proceed another threading operation.

ATTENTION!

The spindle sleeve must be completely retracted in order to trigger the switch point (27).

Pos. Designation Pos. Designation

6 Selector switch for reduction stage 20 Speed control 23 Selection switch operating mode

 automatic  threading  turning direction

24 Push button spindle rotation "ON"

26 Depth stop 27 Adjustable stop cycle end 28 End position switch turning direction

reversal

Version 1.1.4 dated 2015-3-30 Page 33Original operating instructions

BF46 Vario | BF46TC US

4.6 Control and indicating elements BF46TC

Pos. Designation Pos. Designation

1 Pneumatic tool changer 2 Control panel 3 Digital display fine crossfeed of spindle

sleeve

4 Clamping lever for spindle sleeve

5 Meter rule with scale 6 Motor Z-axis feed 7 Spindle protection 8 Activation of the fine adjustment 9 Fine adjustment of spind le sleeve 10 Central lubrication 11 Clamping lever for X-axis 12 Crank handle for saddle slide Y axis 13 Machine base (optionally) 14 Selector switch for reduction stage 15 Control panel tool change

"CLAMPING" / "RELEASING"

16 Clamping screw drilling-milling head right

5 6

11 12 13

14 15

16 17

Version 1.1.4 dated 2015-3-30Page 34 Original operating instructions

BF46 Vario | BF46TCUS

4.6.1 Control panel BF46TC

17 Star grip for spindle sleeve feed 18 Crank handle for manual height adjust-

ment of the drilling milling head 19 Cross table 20 Adjustable limit stops 21 Handle of cross slide for X-axis 22 Clamping lever for Y-axis

Pos. Designation Pos. Designation

26 27 28

Pos. Designation Pos. Designation

23 Potentiometer speed control 24 Digital display speed 32 Control panel tool change:

 Pushbutton "CLAMPING"  Pushbutton "RELEASING"

26 Selection switch operating mode

 automatic

 threading

 turning direction

27 Push button Z feed

(travelling drilling milling head upward)

28 Push button spindle rotation "ON"

29 Push button Z feed

(travelling drilling milling head downward)

30 Push button spindle rotation "OFF"

31 Main switch 14 Selector switch for reduction stage 3 Digital display fine crossfeed of spindle

sleeve

9 Fine adjustment of spindle sleeve

25 EMERGENCY-STOP

Version 1.1.4 dated 2015-3-30 Page 35Original operating instructions

BF46 Vario | BF46TC US

Selection switch for operating mode

With the selector switch the operating mode „automatic, threading or right-hand respectively left-hand run“ is being selected.

Operation mode automatic

Operation mode thread cutting

Rotation direction switch

Standard operation, selection left-handed or right-handed rotation.

Potentiometer

Speed setting "VARIO"

Push button ON

The push button "ON"

switches on the rotation of the spindle.

Push button OFF

The push button "OFF“

switches off the rotation of the spindle.

Main switch

Interrupts or connects the power supply.

4.7 Switching on the mill drill

ATTENTION! Wait until the mill drill has come to a complete halt before changing the rotation

direction using the rotation direction switch. INFORMATION

At a cold mill drill it is possible that with switching on the machine an overload of the drive occur.

Therefore, allow the mill drill at low speeds depending on environmental conditions to warm up for 10 to 20 minutes before you go to maximum speed.

Version 1.1.4 dated 2015-3-30Page 36 Original operating instructions

BF46 Vario | BF46TCUS

Also with a quick on and off, this overload occur. Therefore wait for about 3 seconds before you switch on the mill drill again, the capacitors in the controller must first discharged.

4.8 Switching off the mill drill

 Press the push button "OFF". For a long-term standstill of the mill drill switch it off at the

main switch.

4.9 Traveling the drilling milling head (Z-axis) upward respectively downward

It is possible to perform the height adjustment of the drilling milling head by actuating the crank handle or the control panel

4.9.1 Traveling the drill-mill head upward respectively downward by actuating the crank handle

Img.4-6: Drilling milling head - height adjustment

Img.4-7: Clamping lever

 Release clamping lever (2).  Engage the handle (1) by pushing it towards the teeth.  Crank the drilling milling head to the required position.  Clamp if needed.

1 Crank handle 2 Clamping lever

Version 1.1.4 dated 2015-3-30 Page 37Original operating instructions

BF46 Vario | BF46TC US

4.10 Threading

as described under  "Threading“ on page 32

4.10.1 Traveling the drill-mill head upward respectively downward using the control panel

Img.4-8: Traveling the drilling milling head upward respectively downward using the control panel

 Press the button (1) in order to travel the drilling milling head upward.  Press the button (2) in order to travel the drilling milling head downward.

The end switch (3) limits the vertical movement of the drilling milling head upward respectively downward.

4.11 Inserting a tool on BF46TC

4.11.1 Installation

CAUTION! When milling operations are performed the cone seat must always be fixed to the draw-

The milling head is equipped with a pneumatic tool changer and a M16 extraction rod (draw in bar).

1 Traveling the drilling milling head upward 2 Traveling the drilling milling head downward 3 End switch

Version 1.1.4 dated 2015-3-30Page 38 Original operating instructions

BF46 Vario | BF46TCUS

 Clean the seat in the spindle / quill.  Clean the taper of your tool.  Insert the tool in the spindle / quill.

Img.4-9: Installation tool

 Clamp the tool fixture by actuating the pressure switch "Clamping" on the control panel. The

fixture will be drawn into the spindle. Press the push button switch until the tool is securely clamped.

ATTENTION!

Img.4-10: Installation tool

Make sure that the tool seat is correctly positioned (ISO 40). The tool clamping system must not be activated when the machine is operated.

4.11.2 Unfitting

 Release the tool by actuating the switch "Release“. The fixture comes out of the spindle.  Press the push button switch until the tool is completely detached.

Img.4-11: Extraction tool

Push button "CLAMPING“

Push button "RELEAS-

ING"

Version 1.1.4 dated 2015-3-30 Page 39Original operating instructions

BF46 Vario | BF46TC US

ATTENTION! Hold the tool fixture tight when you detach it. The tool

fixture is pressed out of the spindle.

ATTENTION! The tool clamping system must not be activated when

the machine is operated.

Img.4-12: Extraction tool

ATTENTION! When using an optional MT4 spindle.

When installing a cold morse taper into a heated-up machine those MT seats tend to shrink on the morse taper contrary to the quick-releaser tapers.

Version 1.1.4 dated 2015-3-30Page 40 Original operating instructions

BF46 Vario | BF46TCUS

4.12 Safety

Commission the mill drill only under the following conditions:

 The mill drill is in proper working order.  The mill drill is used as intended.  The operating manual is followed.  All safety devices are installed and activated.

All failures should be eliminated immediately. Stop the mill drill immediately in the event of any abnormality in operation and make sure it cannot be started up accidentally or without authorisation.

 "For your own safety during operation“ on page 15

4.13 Use of collet chucks

When using collet chucks for the reception of milling tools, a higher operation tolerance can be achieved. The exchange of the collet chucks for a smaller or larger end mill cutter is performed simply and rapidly and it is not necessary to disassemble the complete tool. The collet chuck is pressed into the ring of the swivel nut and must rest there by itself. The milling cutter is clamped by fastening the swivel nut on the tool.

Make sure that the correct collet chuck is used for each milling cutter diameter, so that the milling cutter may be fastened securely and firmly.

 "Compressed air supply on BF46TC“ on page 26

4.14 Clamping the workpieces

CAUTION! Injury by flying off parts.

The workpiece is always to be fixed by a machine vice, jaw chuck or by another appropriate clamping tool such as for the clamping claws.

4.15 Changing the speed range

ATTENTION! Wait until the mill drill has come to a complete halt before changing the speed using the

gear switch.

 Select gear level

H = rapid ( 708 - 3100 RPM ) M = middle ( 324 - 1680 RPM ) L = low ( 115 - 720 RPM )

 Adjust the speed with the potentiome-

ter. The speed and thus the cutting speed depends on the material of the workpiece, the milling cu

tter diameter

and the cutter type.

Img.4-13: Drill-Mill head

Selector switch

gear stage

Version 1.1.4 dated 2015-3-30 Page 41Original operating instructions

BF46 Vario | BF46TC US

4.16 Manual spindle sleeve feed with the fine feed

 Turn the handle screw.

The spindle sleeve lever moves in direction of the drilling-milling head and activates the coupling of the fine feed.

 Turn the spindle sleeve fine feed in

order to move the spindle sleeve.

Img.4-14: Handle screw

4.17 Digital display for spindle sleeve travel

Handle screw

Fine feed for

spindle sleeve

Measuring range

0 - 999.99mm 0 - 39.371“

Reading precision

0.01mm

0.0004“

Battery round cell CR2032 , 3 V 20 x 3,2mm

Pos. Description

1 LCD display 2 Shifting mm/inch 3 Performs a value increase in operating mode "S" (Setting) 4 Performs a value decrease in operating mode "S" (Setting) 5 ON/OFF switch 6 Zero position and activation of operation mode "S" 7 Battery compartment 8 Display of operation mode "S" and selected unit "mm / inch"

1 2

Version 1.1.4 dated 2015-3-30Page 42 Original operating instructions

BF46 Vario | BF46TCUS

Operation mode "S"

The operation mode "S" is used to enter and to compensate the mechanic al play (backlash) of quill mechanism.

 (1) Display which shows the op er at ing mo des "S", "inch" or "mm"  (2) converts the measuring unit from millimetres to inches and vice versa.  (3) , Value increase in operation mode "S"  (4) , Value decrease in operation mode "S"  (5) Switches the display ON or OFF.  Resets the display to the set compensation value "S".

Enter the offset value of the quill mechanism

 Press the button (6) for about 2-3 seconds. The operation mode (8) "S" is activated and dis-

played.

 Enter the offset value of a quill mechanism, based on your experience with the keys (3) or

(4).

 Stop the operation mode "S" by pressing the button (6) again.

INFORMATION

Before inserting the new battery, wait about 30 seconds. Please make sure, that the contacts are metallically bright and free from coverings which result from bleeding or gassing batteries. Grip the new batteries only with plastic forceps, if possible not with the hand due to the formation of oxide and never with metal forceps in orde r to avoid a short circuit. In most cases the round cell will be inserted into the digital display with the marking upside. After inserting the round cell, the battery compartment has to be closed again.

4.17.1 Malfunctions

Malfunction Cause / possible effects Solution

Flashing of the display

• Voltage too low • Change battery

Screen doesn’t refresh

• Operation mode "S" is active

• Disturbance in the circuit

• Disable the operation mode "S".

• Remove the battery, wait 30 seconds and reinsert the battery.

No data visible • No power supply

• Battery voltage less than 3V

• Clean battery contacts

• Replace battery

Version 1.1.4 dated 2015-3-30 Page 43Original operating instructions

BF46 Vario | BF46TC US

4.18 Manual spindle sleeve feed with the spindle sleeve lever

ATTENTION! The clutch of the fine feed has to be disengaged before the spindle sleeve lever can be

used. Activating the spindle sleeve lever when the fine feed is engaged may damage the clutch.

 Loosen the handle screw. The sleeve lever moves away from the drilling head and deacti-

vates the coupler of the fine feed.

4.19 Swivelling the drill-mill head

The drill-mill head may be swivelled 45° to the right and to the left. There are to loosen three screws.

Img.4-15: Clamping screws

CAUTION! If the screws are completely unfastened, the drilling-milling head might fall down. When

slewing the working head, only unfasten the screws as far as necessary to be able to perform the settings. After having set the slewing angle, retighte n the fixing screws.

ATTENTION! The drill-mill head can be rotated much further. When slewing it further on gear oil might

escape.

4.20 Selecting the speed

For milling operations, the essential factor is the selection of the correct speed. The speed determines the cutting speed of the cutting edges which cu

t the material. By selecting the cor-

rect cutting speed, the service life of the tool is increased and the working result is optimised. The company cutting speed mainly depends on the material and on the material of the tool. With

tools (milling cutters) made of hard metal or ceramic insert it is possible to work at higher speeds than with tools made of high-alloyed high-speed steel (HSS). You will achieve the correct cutting speed by selecting the correct speed.

In order to determine the correct cutting speed for your tool and for the material to be cut, you may refer to the following standard values or a table reference book (e.g. Machinery's Handbook ISBN 0-8311-2424-5, Insert Pgs. 30a & 30b (attached)).

The required speed is calculated as follows:

Clamping screws

Version 1.1.4 dated 2015-3-30Page 44 Original operating instructions

BF46 Vario | BF46TCUS

4.20.1 Standard values for cutting speeds

[FPM] with high-speed steel and hard metal in conventional milling

Given below are standard values for speeds depending on the milling cutter diameter, cutter type and material.

Tool Steel Grey Cast Iron

A g e - H a r d en e d

Al alloy

Peripherial and side milling (FPM) 33 - 82 33 - 72 492 - 1,148

Relieved form cutters (FPM) 49 - 79 33 - 66 492 - 820

Inserted tooth cutter with SS (FPM) 49 - 79 39 - 82 656 - 984

Inserted tooth cutter with HM (FPM) 328 - 656 98 - 328 984 - 1,312

Tool diameter (in.)

Peripheral and side milling cutters

Steel Grey Cast Iron

Age-Hardened

Al alloy

33 - 82 FPM 33 - 72 FPM 492 - 1,148 FPM

Speed (RPM)

1.378" 91 - 227 91 - 200 1,365 - 3,185

1.575" 80 - 199 80 - 175 1,195 - 2,790

1.772" 71 - 177 71 - 156 1,062 - 2,470

1.969" 64 - 159 64 - 140 955 - 2,230

2.165" 58 - 145 58 - 127 870 - 2,027

2.362" 53 - 133 53 - 117 795 - 1,860

2.559" 49 - 122 49 - 108 735 - 1,715

Tool diameter (in.)

Form cutters

Steel Grey Cast Iron

Age-Hardened

Al alloy

49 - 79 FPM 33 - 66 FPM 492 - 820 F PM

Speed (RPM)

0.1575" 1,194 - 1,911 796 - 1,592 11,900 - 19,000

0.1969" 955 - 1,529 637 - 1,274 9,550 - 15,900

0.2362" 796 - 1,274 531 - 1,062 7,900 - 13,200

0.3150" 597 - 955 398 - 796 5,900 - 9,900

0.3937" 478 - 764 318 - 637 4,700 - 7,900

0.4724" 398 - 637 265 - 531 3,900 - 6,600

0.5512" 341 - 546 227 - 455 3,400 - 5,600

0.6299" 299 - 478 199 - 398 2,900 - 4,900

Version 1.1.4 dated 2015-3-30 Page 45Original operating instructions

BF46 Vario | BF46TC US

4.20.2 Standard values for speeds with HSS – Eco – twist drilling (U.S. unit)

1: Speed (n) in RPM 2: Feed Rate (f) in./rev. 3: Coolant: E = Emulsion; Oil = Cutting oil

The above mentioned indications are standard values. In some cases it may be

advantageous to increase or decrease these values.

When drilling a cooling or lubricating agent should be used. For stainless materials (e.g. VA – or NIRO steel sheets) do not center as the material

would compact and the drill bit will become rapidly blunt.

The workpieces need to be tensed in flexibly and stably (vice, screw clamp).

INFORMATION

High temperatures are generated at the tip of the tool by the occurring friction heat. The tool should be cooled during the milling process. Cooling the tool with a suitable cooling lubricant ensures better working results and a longer edge life of the cutting tool.

INFORMATION

Use a water-soluble and non-pollutant emulsion as a cooling agent.This can be acquired from authorised distributors.

Make sure that the cooling agent is properly retrieved. Respect the environment when disposing of any lubricants and coolants. Follow the manufacturer’s disposal instructions.

Material

Cutter Diameter (in.)

Coolant

0,0787 0,1181 0,1575 0,1969 0,2362 0,2756 0,3150 0,3543 0,3937

Steel, unalloyed, up

to 87,000 PSI

5.600 3.550 2.800 2.240 2.000 1.600 1.400 1.250 1.120

0,0016 0,0025 0,0031 0,0039 0,0049 0,0049 0,0063 0,0063 0,0079

Structural steel, alloyed,

quenched and subse-

drawn, up to 130,000 PSI

3.150 2.000 1.600 1.250 1.000 900 800 710 630

E/Oil

0,0013 0,002 0,0025 0,0031 0,0039 0,0039 0,0049 0,0049 0,0063

Structural steel, alloyed,

quenched and subse-

drawn, up to 174,000 PSI

2.500 1.600 1.250 1.000 800 710 630 560 500

Oil

0,0013 0,0016 0,0020 0,0025 0,0031 0,0039 0,0039 0,0049 0,0049

Stainless steels up to

130,000 PSI e.g.,

X5CrNi18 10

2.000 1.250 1.000 800 630 500 500 400 400

Oil

0,0013 0,0020 0,0025 0,0031 0,0039 0,0039 0,0049 0,0049 0,0063

Version 1.1.4 dated 2015-3-30Page 46 Original operating instructions

BF46 Vario | BF46TCUS

5 Maintenance

In this chapter you will find important information about

 Inspection  Maintenance  Repair

of the mill drill

ATTENTION! Properly performed regular maintenance is an essential prerequisite for

 operational safety,  failure-free operation,  long service life of the mill drill and  the quality of the products which you manufacture.

Installations and equipment from other manufacturers must also be in good order and condition.

5.1 Safety

WARNING! The consequences of incorrect maintenance and repair work may include:

 Very serious injury to personnel working on the,  Damage to the mill drill.

Only qualified staff should carry out maintenance and repair work on the mill drill.

5.1.1 Preparation

WARNING! Only carry out work on the mill drill if it has been disconnected from the mains power

supply.

 "Disconnecting and securing the mill drill“ on page 15

Attach a warning sign.

5.1.2 Restarting

Before restarting run a safety check.

 "Safety check“ on page 14

WARNING! Before starting the mill drill, you must check that there is no danger for persons and that

the mill drill is not damaged.

5.2 Inspection and maintenance

The type and level of wear depends to a large extent on the individual usage and operating conditions. For this reason, all the intervals are only valid for the authorised conditions.

Interval Where? What? How?

Start of work,

after every

maintenance or

repair work

Mill drill

 "Safety check“ on page 14

Version 1.1.4 dated 2015-3-30 Page 47Original operating instructions

BF46 Vario | BF46TC US

Start of work, after every

maintenance or repair work

Cross table / drill-mill head

Oiling

 Actuate the central lubrication of the cross table and of the

drill-mill head with five pump strokes. If required refill acidfree oil in the tank of the central lubrication.

Fig.5-1: Central lubrication

Every week

Cross table

Oiling

 Oil all bare steel surfaces. Use an acid-free oil, e.g.

weapon oil or motor oil.

Every week

Gear milling head

Oil level

 Check the oil level of the gear. The oil level must be in the

middle of the sight glass.

Fig.5-2: Oil sight glass gear

Interval Where? What? How?

Filling hole

Oil sight glass

Version 1.1.4 dated 2015-3-30Page 48 Original operating instructions

BF46 Vario | BF46TCUS

First after 200 operatingm hours, then every 2000 operating hours

Gear milling head

Oil change

 For oil change use an appropriate collecting tray of suffi-

cient capacity.

 Have the mill drill run for a few minutes, the oil will heat up

and will slightly penetrate from the opening.

 Remove the ventilation screw from the gear.  Remove the oil drain plug.  Refill the oil over the removed ventilation screw.

Quantity and type of oil

 "Operating material“ on page 18

Fig.5-3: Milling head

Interval Where? What? How?

Oil drain plug

Ventilation screw of the gear

Version 1.1.4 dated 2015-3-30 Page 49Original operating instructions

BF46 Vario | BF46TC US

As required

Spindle nut cross table

Readjusting

An extended clearance in th e spindles of the cross table can be reduced by readjusting the spindle nuts.

Fig.5-4: Spindle nut X - axis (milling table faded out)

The spindle nuts are readjusted by reducing the thread flanks of the spindle nut by means of a regulating screw. Due to th e readjustment it is necessary to check if a smooth movement over the whole travel is still given, otherwise the wear is considerably increased due to the friction between the spindle nut and the spindle.

The regulating screw of the spindle nut of the Y axis is accessible from the rear side, the regulating screw of the spindle nut of the x axis is accessible from the right or left side of the milling table.

As required

V-ledges

Readjusting X and Y axis

Fig.5-5: Cross table

 Turn the adjusting screw of the respective taper gib

frontand rear, or left and right in the clockwise direction. The taper gib is continued to push in and reduced by it the gap in the guide

way.

 Check the settings. The corresponding guideway must be

more easily moveable but ensure a stable guiding.

Interval Where? What? How?

Spindle nut adjusting screw

Cross table

Regulating screw V-ledge

X axis right side

Regulating screw V-ledge

Y axis front

Version 1.1.4 dated 2015-3-30Page 50 Original operating instructions

BF46 Vario | BF46TCUS

INFORMATION

The spindle bearing is lifetime-lubricated. It is not necessary to lubricate it again.

5.3 Repair

Repairs must be carried out only by qualified technical staff; and must follow the instructions and guidelines given in this manual. Should technical assistance be required, contact C.H.HANSON at (630) 785-6437.

Company and C.H.HANSON are not liable for, nor do they guarantee against, damage or operating malfunctions resulting from alteration, abuse, lack of main-tenance or this product’s use for other than its intended purpose. Failure to read and follow this operating manual is not covered.

For repairs only use

 Proper and suitable tools,  Parts purchased from company, or its authorized agent.

As required

V-ledges

Readjusting Z axis:

Fig.5-6: Column and mill head

 Proceed as described under "Readjusting X and Y axis".

Interval Where? What? How?

Regulating screw V-ledge

Z-axis top

Regulating screw V-ledge

Z-axis bottom

Version 1.1.4 dated 2015-3-30 Page 51Original operating instructions

BF46 Vario | BF46TC US

1Spare parts

1.1 Milling head 1 - 3

Fig.1-1: Milling head 1 - 3

Version 1.1.4 dated 2015-3-30Page 52 Original operating instructions

BF46 Vario | BF46TCUS

1.2 Milling head BF 46 TC Vario

Fig.1-2: Milling head BF46 TC Vario

Version 1.1.4 dated 2015-3-30 Page 53Original operating instructions

BF46 Vario | BF46TC US

1.3 Milling head 2 - 3

Fig.1-3: Fräskopf - Milling head 2 - 3

Version 1.1.4 dated 2015-3-30Page 54 Original operating instructions

BF46 Vario | BF46TCUS

1.4 Milling head 3 - 3

Fig.1-4: Fräskopf - Milling head 3 - 3

1.5 Milling head BF46TC

Fig.1-5: Fräskopf - Milling head BF46 TC Vario

202

192

203

190

193

189

188

187

186-1

186

195

185

313

265

267

Version 1.1.4 dated 2015-3-30 Page 55Original operating instructions

BF46 Vario | BF46TC US

1.6 Column

Fig.1-6: Column

Version 1.1.4 dated 2015-3-30Page 56 Original operating instructions

BF46 Vario | BF46TCUS

1.7 Column BF46TC

Fig.1-7: Column BF46 TC Vario

Version 1.1.4 dated 2015-3-30 Page 57Original operating instructions

BF46 Vario | BF46TC US

1.8 Cross table 1 - 2

Fig.1-8: Cross table 1 - 2

Version 1.1.4 dated 2015-3-30Page 58 Original operating instructions

BF46 Vario | BF46TCUS

1.9 Cross table 2 - 2

Fig.1-9: Cross table 1 - 2

Version 1.1.4 dated 2015-3-30 Page 59Original operating instructions

BF46 Vario | BF46TC US

1.10 Protection device

Fig.1-10: Protection device

Version 1.1.4 dated 2015-3-30Page 60 Original operating instructions

BF46 Vario | BF46TCUS

1.11 Machine stand (option)

Fig.1-11: Machine stand (option)

Version 1.1.4 dated 2015-3-30 Page 61Original operating instructions

BF46 Vario | BF46TC US

1.11.1 Spare parts list

BF46 Vario │ BF46 TC

Pos.

Description Qty. Drawing no. Size Article no.

1 Connect board 1 1015119 0333845301 2 Socket head screw 1 ISO 4762 M3 x 10 3 Digital indicator 1 DQ-02A 0333845303 5 Hexagon screw 1 DIN 912 M12 x 50 6 O-ring 1 DIN 3771 77.5 x 5.3 0333845306

Pinole 1 1015105b 0333845307 Pinole 1 1015105

Taper roller bearing ISO40 1 33209_Q 04033209

Taper roller bearing MT4, option 1 33208_Q

Spindle R8 1 R8 0333845309y

Spindle ISO 40, option 1 1015101_SK40 SK40 0333845309

Spindle MT4, option 1 1015101_MK4 MK4 10 Taper roller bearing 1 33007 04033007 11 Set screw 1 DIN 915 M10 x 25 12 Hexagon nut 1 DIN 934 M10 13 Snap ring 1 DIN 472 80 x 2.5 0333845313 14 Grooved ball bearing 1 6011-2RZ 0406011.2R 15 Clamping nut 1 1015106 0333845315 16 Hexagon screw 2 DIN 912 M5 x 12 17 Support 1 1015103b 0333845317 18 Hexagon screw 1 DIN 912 M8 x 20 19 Set screw 2 DIN 915 M4 x 8 20 Washer 11 DIN125 A 16 21 Lock washer 1 DIN 127 A 16 0333845321 22 Hexagon nut 7 ISO 4032 M16 23 Washer 1 DIN 125-2 17 24 Lock washer 7 DIN 128 A16 0333845324 25 Hexagon screw 1 ISO 4017 M16 x 60 26 Pinion shaft 1 1015135 0333845326 27 Grooved ball bearing 2 6003 0406003.2R 28 Oil sight glas 1 0333845328 29 O-ring 1 DIN 3771 20 x 2.65 - N - NBR 70 0333845329 30 Hexagon screw 1 AS 2465 3/8 x 1/2 UNC 0333845330 31 Copper washer 1 10 0333845331 32 Toothed drive shaft 1 1015107 0333845332 33 Key 1 DIN 6885 A10 × 6 × 18 0333845333 34 Snap ring 2 DIN 471 48 0333845334 35 Gear 55 1 1015108 0333845335 36 Holder drawin bar 1 1015141 0333845336

Drawin bar R8 0333845337y

Drawin bar ISO40 1 1015701b M16 0333845337

Drawin bar MT4 1 1015701 0333845337MK4

38a Shaft, year of manufacture to 2011 1 1015113 0333845338a

38 Shaft, year of manufacture from 2011 1 0333845338 39 Gear 37T 1 up to year 2006 straight teeth 0333845339A 39 Gear 37T 1 from year 2006 helical teeth 0333845339 40 Key 1 DIN 6885 A 6 x 6 x 10 0333845340 41 Key 1 DIN 6885 A 6 x 6 x 70 0333845341 42 Snap ring 1 DIN 471 17 0333845342 43 Snap ring 1 DIN472 35 0333845343

44a Gear, year of manufacture up to 2011 1 1015114 0333845344a

44 Gear, year of manufacture from 2011 1 0333845344 45 Key 1 DIN 6885 A 6 x 6 x 16 0333845345 46 Gear 47 1 1015115 0333845346 47 Gear 33 1 1015116 0333845347 48 Snap ring 1 DIN 471 32 0333845348 49 Milling head housing cover 1 1015109 0333845349 50 Snap ring 1 DIN 472 55 0333845350 51 Grooved ball bearing 2 6307.2R 0406307R 52 Gear wheel 1 1015117 1015117 0333845352 53 Motor 1 Motor 2,2 KW 0333845353 54 Key 1 DIN 6885 A 6 x 6 x 36 0333845354 55 Snap ring 1 DIN 471 32 x 1.5 0333845355 56 Grooved ball bearing 1 6308-2RZ 0406308.2R 57 Bearing cover 1 1015110 0333845357 58 Socket head screw 13 ISO 4762 M5 x 12 59 Vent screw 1 1015142 0333845359 60 Socket head screw 6 ISO 4762 M8 x 40 61 Cylindrical pin 2 ISO 8734 8 x 50 - A 0333845361

Version 1.1.4 dated 2015-3-30Page 62 Original operating instructions

BF46 Vario | BF46TCUS

62 Washer 7 DIN 125 8 63 Socket head screw 27 ISO 4762 M8 x 25 64 Clamping bolt 1 1015138 0333845364 65 Clamping bolt 1 1015139 0333845365 66 Clamping lever 1 0333845366 67 Taper gear wheel 35 1 1015133 0333845367 68 Worm shaft 1 1015129 0333845368 69 Scale ring 1 1015130 inch 0333845369y 70 Knurling tool 1 1015131 0333845370 71 Spring plate 4 D140-04-09 0333845371 72 Set screw 1 DIN 916 M6 x 8 73 Hub 1 1015134 0333845373 74 Lever 3 0333845374 74 Lever year of manufacture 05/2009 3 03338430227 75 Key 1 DIN 6885 A 8 x 7 x 20 0333845375 76 Threaded rod 1 1015128-2 0333845376 77 Compression spring 1 2×14×30-3 2×14×30-3 0333845377 78 Knurling tool 1 1015128-1 0333845378 79 Spring pin 1 ISO 13337 3 × 25

80 Measuring ruler digital display 1 0333845380 80-1 Protective cover 1 03338453801 80-2 Socket head screw !

81 Drilling depth stop 1 1015122 0333845381

82 Threaded rod 1 1015121 0333845382

83 Knurling tool 1 1015123 0333845383

84 Spring pin 1 ISO13337 3 × 14

85 Driving disk 1 1015136 0333845385

86 Hexagonal screw with slot 1 ISO 1207 M5 x 10

87 Return spring 1 1015137 0333845387

88 Screw 2 DIN427 M3 × 10

89 Return spring housing 1 1015120 0333845389

90 Disk 1 1015140 0333845390

91 Socket head screw 1 ISO 4762 M6 x 10

92 Choice rotary switch transmission 1 1015132 0333845392

93 Shaft 1 1015127 0333845393

94 Set screw 1 DIN 914 M5 x 16

95 O-ring 1 DIN 3771 6.9 × 1.8 G 0333845395

96 Support shift fork 1 1015126 0333845396

97 O-ring 1 DIN 3771 20 x 3.55 - N - NBR 70 0333845397

98 Screw 3 ISO 10642 M5 × 10

99 Set screw 1 DIN 913 M8 x 8

100 Steel ball 1 GB-T308-1994 6.5 03338453100 101 Position cover choice rotary switch 1 1015506 03338453101 102 Arm shift fork 1 1015125 03338453102 103 Set screw 1 DIN 913 M5 x 8 104 Shift fork 1 1015124 03338453104 105 Snap ring 1 DIN 471 10 × 1 03338453105 106 Socket head screw 6 ISO 4762 M4 x 8 107 Motor cover 1 1015111 03338453107 108 Cover cap 1 DM14-01-09 03338453108 109 Hexagon screw 2 ISO 4014 M16 x 65 110 Hexagon screw 1 ISO 4014 M16 x 80 111 Taper gib 1 1015119 03338453112 113 Adjusting screw 6 1015002 03338453113 114 Angle scale 1 1015502 03338453114 116 Socket head screw 1 ISO 4762 4762-M4 × 8 117 Column 1 1015301 03338453117 118 Scale 1 1015503 inch 03338453118y 120 Machine base 1 1015202 03338453120 121 Hexagon screw 4 ISO 4014 M16 x 70 122 Machine stand, option 1 1015702 3353005

123

Zero point - linear measurement cross

table

1 1015204 03338453123

124 Cross table guidance 1 1015210 03338453124 125 Socket head screw 28 ISO 4762 M8 x 16 126 Spindle nut x-axis 1 1015208 inch 03338453126y 127 Socket head screw 2 ISO 4762 M5 x 20 128 Grease nipple 8 0340114 129 Brass pin 6 03338453129 131 Taper gib x-axis 1 1015207 03338453131 132 Taper gib y-axis 1 1015215 03338453132

BF46 Vario │ BF46 TC

Pos.

Description Qty. Drawing no. Size Article no.

Version 1.1.4 dated 2015-3-30 Page 63Original operating instructions

BF46 Vario | BF46TC US

134 Milling table 1 1015209 03338453134 135 Bearing block x-axis 1 1015219 03338453135 136 Cylindrical pin 6 ISO 2338 8 h8 x 35 03338453136 137 Bearing block x-axis 1 1015218 03338453137 138 Slots stone end stop x-axis 2 1015206 03338453138 139 Bushing end stop x-axis 2 1015205 03338453139 140 Spacer ring x-axis 2 1015220 03338453140 141 Grooved ball bearing 5 6004 6004 0406004.2R 142 Spindle x-axis 1 1015216 inch 03338453142y 143 Key 3 DIN 6885 A 6 x 6 x 14 03338453143 144 Handwheel

3 1015211 03338453144 145 Scale ring 3 1015213 inch 03338453145y 146 Clamping nut 3 1015212 03338453146 147 Set screw 3 DIN 913 M16 x 20 148 Handle complete 4 JB-T7270.4-1994 03338453148

148-1 Bushing 4 033384531481 148-2 Screw 4 033384531482

149

Screwing in connection coolant drain-

age

1 1015217 03338453149 150 Bearing block y-axis 1 1015201 03338453150

151 Spindle nut y-axis 1 1015214 inch 03338453151y 152 Spindle y-axis 1 1015203 inch 03338453152y 153 Bearing block y-axis 1 1015221 03338453153 154 Grooved ball bearing 4 6004-2Z 6004-2Z 0406004.2R 155 Snap ring 1 DIN 472 45 x 1.75 03338453155 156 Spindle cover 2 1015222 03338453156 158 Bearing block 1 1015308 03338453158 159 Scale x-axis 1 1015504 inch 03338453159y 160 Plate 1 03338453160 161 Spacer 1 1015302 03338453161 162 Taper gear 42 1 1015303 03338453162 163 Spacer 1 1015305 03338453163 164 Flange 1 1015306 03338453164 165 Spindle nut z-axis 1 1015307 03338453165 166 Spacer 1 1015310 03338453166 167 Shaft 1 1015311 03338453167 168 Disk 1 1015312 03338453168 169 Bearing block z-axis 1 1015313 03338453169 170 Cover plate column 1 1015314 03338453170 171 Bearing cover 1 1015315 03338453171 172 Spindle nut z-axis 1 1015316 inch 03338453172y 173 Spindle nut z-axis 1 1015317 inch 03338453173y 174 Socket head screw 4 ISO 4762 M8 x 12 175 Key 1 DIN 6885 A 5 x 5 x 20 03338453175 176 Key 1 DIN 6885 A 6 x 6 x 20 03338453176 177 Socket head screw 8 ISO 4762 M6 x 16 178 Snap ring 2 DIN 472 42 x 1.75 03338453178 179 Skew-angle roller bearing 1 3204 A 0403204A.2R 180 Spindle z - axis 1 1015309 inch 03338453180y 181 Groove nut 2 DIN 1804 M16 03338453181 182 Door machine stand 1 1015702_1 03338453182 183 Washer 4 DIN 9021 17 184 Hexagonal screw 4 DIN 6914 M16 x 85 185 Switch R/L 1 03338453185 186 Potentiometer 1 03338453186

186-1 Knob 1 033384531861

187 Push button off 1 03338453187 188 Push button on 1 03338453188 189 Emergency OFF push button 1 03338453189 190 Main switch 1 03338453190

191

Socket head screw with countersunk

head

14 ISO 10642 M4 × 6

192 Electric box - cover 1 1015402 03338453192 193 Electric box - housing 1 1015401 03338453193 194 Electric box - cover 1 BF46-FL223-003 03338453194 195 Socket head screw 4 ISO 4762 M3 x 12 198 Bellows

1 1015004 03338453198 199 Clamping lever 6 03338453199 200 Socket head screw 1 ISO 4762 M10 x 16 201 Rubber cover 1 03338453201 202 Control board 1 03338453700 03021303201

BF46 Vario │ BF46 TC

Pos.

Description Qty. Drawing no. Size Article no.

Version 1.1.4 dated 2015-3-30Page 64 Original operating instructions

BF46 Vario | BF46TCUS

203 Strain relief lead switchbox 2 03338453203 204 Set screw 2 DIN 913 M6 x 25 205 Cylindrical pin 1 ISO 8733 8 x 40 206 Housing milling head 1 1015104 03338453206 207 Compression spring 1 0.8×5×25-3 03338453207 208 Radial rotary shaft seal 1 CR 55x80x8 HMS4 R 03338453208 209 Zero point - scale 1 B26-02-27 03338453209 210 Centerring piece pinole 1 B26-02-04 03338453210 211 Center ring scale 1 1015319 03338453211 212 Crank 1 B26-01-09 03338453212 213 Scale 1 1015318 inch 03338453213y 215 Electronic display 1 03338453215 214 Electric box - switch plate 1 1015403 03338453214 216 Threaded pin 1 M6 x 8 M6 x 8 217 Attaching bracket 1 03338453217

221 Support 1 03338453221 221-1 Housing 1 033384532211 221-2 Steel ball 1 033384532212 221-3 Spring plate 1 033384532213 221-4 Screw 2 033384532214 221-5 Micro switch 1 033384532215 221-6 Aluminium profile admission 1 033384532216 221-7 Cover 1 033384532217

222 Clamping scew 1 03338453222

223 Attaching bracket 1 03338453223

224 Socket head screw 2 03338453224

225 Sensor end position below 1 03338453225 225-1 Sensor end position top 1 033384532251 225-2 Rotation speed sensor 1 033384562252

226 Nut 4 03338453226

227 Socket head screw 2 03338453227

228 Socket head screw 1 03338453228

229 Aluminium profile 1 03338453229

230 Protection 1 03338453230

231 Washer 2 03338453231

232 Socket head screw 2 03338453232

233 indicator

drilling depth stop 1 03338453233

234 Socket piece milling tool 2 03338453234

235 Socket head screw 2 GB 70 - 85 M8 x 16

237 Taper gear wheel 21 teeths 1 1015304 03338453236

238 Groove nut 2 1015323 03338453238

239 Spacer 1 1015322 03338453239

240 Bearing cover 1 1015320 03338453240

241 Socket head screw 3 GB 70 - 85 M6x25

242 Bearing block 1 1015308b 03338453242

243 Spacer 1 101531 03338453243

245 Chip tray 2 03338453245

246 Gear 1 03338453246

247 Holder sensor 1 03338456247

248 Drawin bar 1 03338456248

250 Plate 1 03338456250

251 Washer 1 DIN 125/6

252 Hexagon socket screw 3 DIN 4762-M6x25

253 Hexagon socket screw 4 DIN 4762-M8x70

254 Cover 1 03338456254

255 Angle 1 03338456255

256 Hexagon socket screw 3 DIN 4762-M5x12

257 Washer 3 DIN 125/6

258 Button On 1 03352394125

259 Switch box 1 03352394123

260 Button Off 1 03352394126

261 Cover switch box 1 03352394127

262 Air tube 4 mm 03338453262

263 Air tube 8 mm 03338456263

264 Cover 1 03338456264

265 Cover 1 03338456265

267 Button 2 03338456267

268 3-way distributor 1 03338456410

269 Plug 2 03338453269

270 Adapter 1 03338453270

BF46 Vario │ BF46 TC

Pos.

Description Qty. Drawing no. Size Article no.

Version 1.1.4 dated 2015-3-30 Page 65Original operating instructions

BF46 Vario | BF46TC US

271 Plug 1 03338453271 272 Oiler 1 03336020001 273 Cover 1 03338456273

274 Motor 1

MBL-123IM-300HA-S

Hall Sensor 120°

14 amps

2.2 KW

0333845353

275 Hexagon socket screw 4 DIN 4762-M6x30 276 Washer 4 DIN 125/6 277 Hexagon socket screw 4 DIN 4762-M8x25 278 Washer 4 DIN 125/8 279 Washer 4 DIN 125/6 280 Spring washer 4 DIN 129/6 281 Hexagon nut 4 DIN 4032/M6 282 Gear box 1 03338456282 283 Fitting key 1 DIN 6885/5x5x14 284 Endswitch 2 03338456284 285 Flange 1 03338456285 286 Hexagon socket screw 4 DIN 4762-M8x25 287 Grub screw 2 DIN 4026/M5x12 288 End stop 1 03338456288 289 End stop 2 03338456 290 Fitting key 1 DIN 6885/5x5x12 291 Shaft 1 03338456291 292 Crown gear 1 03338456292 293 Spring 1 03338456293 294 Crank 1 03338456294 295 Sleeve 1 03338456295 296 Washer 1 03338453296 297 Hexagon socket screw 1 DIN 4762-M5x20 298 Cover control box 1 0335239488 299 Control box 1 0335239490 300 Electric valve 1 0335239492 301 T-fiting with quick connector 1 0335239497 302 Quick connector 1 03352394122 303 Signal lamp 1 03352394114 304 Fuse 1 4A 03352394116 305 Fuse housing cpl. 1 03338453305 306 Maintenance unit 1 03352394138 307 Quick connector 2 03352394137 308 Air tube 13 mm 03352394135 309 Plug 1 03338453309 310 Plug 1 03338453310 311 Pneumatic cylinder 1 0335239481 312 Column BF46TC Vario 1 03338456312 313 Holder control panel 1 03338430377

BF46 Vario │ BF46 TC

Pos.

Description Qty. Drawing no. Size Article no.

Version 1.1.4 dated 2015-3-30Page 66 Original operating instructions

BF46 Vario | BF46TCUS

1.12 Wiring diagram 1 of 2/ BF46, BF46TC

Fig.1-12: Wiring diagram 2 of 2/ BF46, BF46TC

Version 1.1.4 dated 2015-3-30 Page 67Original operating instructions

BF46 Vario | BF46TC US

1.13 Wiring diagram 2 of 2/ BF46TC

Fig.1-13: Wiring diagram 2 of 2/ BF46TC

Version 1.1.4 dated 2015-3-30Page 68 Original operating instructions

BF46 Vario | BF46TCUS

1.13.1 Parts list electrical components BF46 Vario, BF46TC Vario

Pos.

Description Qty. Size Article no.

Parts list electrical komponents for BF46 Vario, BF46TC Var i o 1S0 Main switch 1 LW8GS-20104-2/660V,20A 03338453190 1A0 Brushlesscontroller 1 03021303201

1F0 Fuse 1 10A 033384531F0

1Z0 Line filter 1 033384531Z0 1B1 Milling chuck safety switch 1 0302024153-4 1S1 Emergency-Stop button 1 LA103/10A, 660V 03338453189

1F1 Fuse 1 10A 033384531F0 1M2 Drive motor 1 0333845353 1S3 Button On 1 LA103XD-22/36V,10A 03338430386 1S4 Button Off 1 LA103 03338453187 1S5 Functional switch 1 Kraus&Naimer/ F89580/001 03338453185 1B5 Upper end position sensor 1 03021303225 1B6 Lower end position sensor 1 03021303230 1R7 Potentiometer 1 WX14-12/4K7 03338120R1.5 1B8 Speed sensor 1 033384532252 1A8 Rotation speed indicator 1 SN100304 03338120P1.3

Parts list electrical components only for BF46TC Vario

2S0 Button tool changer 1 SHAN-HO/ 6A, 250V AC 03352394125

2F0 Fuse 1 4A 03352394116 2S1 Button tool changer 1 SHAN-HO/ 6A, 250V AC 03352394126 2H1 Work light 1 24V 03352394114 2Y1 Solenoid valve 1 Amisco 24V, 5A 0335239492 2S3 Button feed z-axis 1 LA130/ 400V, 12A 03338453267 2S4 Button feed z-axis 1 LA130/ 400V, 12A 03338453267 2B5 Endswitch 1 Delixi 220V/3A 03338453284

2M6 Z-axis feed motor 1

220V, 120W, 0,95A,

1350 rpm

03338453274

2B6 Endswitch 1 Delixi 220V/3A 03338453284 2C7 Capacitor 1 7µF/150V 033384562C7

Version 1.1.4 dated 2015-3-30 Page 69Original operating instructions

BF46 Vario | BF46TC US

1.14 Lubrication diagram

Fig.1-14: Lubrication diagram

1.14.1 Lubricating unit

Pos.

Description Qty. Size Article no.

1 Oiler 1 03336020001 2 L- Connector 8 M10x1 03338456402 3 Oil tube 4mm 03338456403 4 Protecting cap 14 03338456404 5 T- Connector 1 03338456405 6 L- Connector 2 03338456406 7 Series connection 2 M10x1 03338456407 8 Screwing 3 M10x1 03338456408

9 Series connection 1 03338456409 10 Manifold 1 03338456410 11 Connector screw 1 03338456411 12 Manifold 1 03338456412 13 Tube protection 03338456413

Version 1.1.4 dated 2015-3-30Page 70 Original operating instructions

BF46 Vario | BF46TCUS

1.1.4 2015-03-30 71

Lubricant

Viskosity

ISO VG

DIN 51519

mm²/s (cSt)

Designation

according

DIN 51502

Gear oil

VG 680 CLP 680

Aral Degol

BG 680

BP Energol GR-XP 680

SPARTAN

EP 680

Klüberoil

GEM 1-680

Mobilgear

636

Shell Omala

680

Meropa 680

VG 460 CLP 460

Aral Degol

BG 460

BP Energol GR-XP 460

SPARTAN

EP 460

Klüberoil

GEM 1-460

Mobilgear

634

Shell Omala

460

Meropa 460

VG 320 CLP 320

Aral Degol

BG 320

BP Energol GR-XP 320

SPARTAN

EP 320

Klüberoil

GEM 1-320

Mobilgear

632

Shell Omala

320

Meropa 320

VG 220 CLP 220

Aral Degol

BG 220

BP Energol GR-XP 220

SPARTAN

EP 220

Klüberoil

GEM 1-220

Mobilgear

630

Shell Omala

220

Meropa 220

VG 150 CLP 150

Aral Degol

BG 150

BP Energol GR-XP 150

SPARTAN

EP 150

Klüberoil

GEM 1-150

Mobilgear

629

Shell Omala

150

Meropa 150

VG 100 CLP 100

Aral Degol

BG 100

BP Energol GR-XP 100

SPARTAN

EP 100

Klüberoil

GEM 1-100

Mobilgear

627

Shell Omala

100

Meropa 100

VG 68 CLP 68

Aral Degol

BG 68

BP Energol

GR-XP 68

SPARTAN

EP 68

Klüberoil

GEM 1-68

Mobilg

ear

626

Shell Omala

Meropa 68

VG 46 CLP 46

Aral Degol

BG 46

BP Bartran

NUTO H 46

(HLP 46)

Klüberoil

GEM 1-46

Mobil DTE

Shell T ellus

S 46

Anubia EP

VG 32

Aral Degol

BG 32

BP Bartran

NUTO H 32

(HLP 32)

LAMORA

HLP 32

Mobil DTE

Shell T ellus

S 32

Anubia EP

Gear grease G 00 H-20

Aral FDP 00

(Na-verseift)

Aralub MFL

00 (Li-ver-

seift)

BP Energrease

PR-EP 00

FIBRAX EP

370 (Na-ver-

seift)

MICRO-

LUBE GB 00

Mobilux EP

004

Shell Alvania

GL 00 (Li-

verseift)

Marfak 00

Bearing grease

K 3 K-20

(Li-

verseift)

Aralub HL 3

BP Energrease

LS 3

BEACON 3

CENTO-

PLEX 3

Mobilux 3

Shell Alvania

R 3 Alvania

G 3

Multifak

Premium 3

Version 1.1.4 dated 2015-3-30Page 72 Original operating instructions

BF46 Vario | BF46TCUS

2 Malfunctions

Malfunction Cause / possible effects Solution

The mill drill does not start • Power-on sequence ignored. •  "Switching on the mill drill“ on

page 30 and

 "Switching on the

mill drill“ on page 35

• Have it checked by authorised personnel.

Tool "burnt". • Incorrect speed.

• Chips do not come out of the bore hole

• Tool blunt. Operating without cooling agent.

• Select another rate, feed too high.

• Pull out tool more often. Sharpen or replace tool.

• Use cooling agent

Impossible to insert grip cone into the spindle sleeve.

• Remove any dirt, grease or oil from the internal conical surface of the spindle sleeve or the grip cone.

• Clean surfaces well Keep surfaces free of grease.

It is not possible to push-out the taper.

• Optional MT4 taper is shrinked on the Morse taper.

• Let the machine run at highest speed for two minutes in order to warm it up and then retry to disassemble the taper.

Motor does not start • Defective fuse. • Have it checked by authorised per-

sonnel.

Working spindle rattling on rough piece surfaces

• Climb milling machining not possible under the current operating conditions.

• Clamping lever of the movement axes not tightened.

• Loose collet chuck, loose drill chuck, loose draw-in rod.

• Tool is blunt.

• The workpiece is not fastened.

• Excessive slack in bearing.

• Working spindle goes up and down.

• Perform conventional milling.

• Tighten clamping lever

• Check, re-tighten.

• Sharpen or replace tool

• Clamp the workpiece firmly.

• Readjust bearing slack or replace bearing

Fine feed of the spindle sleeve does not work

• Fine feed is not correctly activated.

• Coupling of the fine feed does not camin, is soiled, blurred, worn, defective

•

 "Manual spindle sleeve feed

with the fine feed“ on page 41

• Clean, replace.

Digital display •

 "Malfunctions“ on page 42

Version 1.1.4 dated 2015-3-30 Page 73Original operating instructions

BF46 Vario | BF46TC US

3 Appendix

3.1 Copyright

This document is copyright. All derived rights are also reserved, especially those of translation, re-printing, use of figu res, broadcast, reproduction by photo-mechanical or similar means and recording in data processing systems, neither partial nor total.

Subject to technical changes without notice.

3.2 Terminology/Glossary

Term Explanation

Cross table Bearing surface, clamping surface for the workpiece with X- and Y-axis

travel Taper mandrel Cone of the drill or of the drill chuck Workpiece Piece to be milled, drilled or machined. Draw-in rod Threaded rod to fix the taper mandrel in the spindle sleeve. Drill chuck Drill bit chuck Collet chuck Holder for end mill Drill-Mill head Upper part of the mill drill Spindle sleeve Hollow shaft in which the milling spindle turns. Milling spindle Shaft activated by the motor Drilling table Supporting surface, clamping surface Taper mandrel Cone of the drill or of the drill chuck Spindle sleeve lever Manual operation for the drill feed Quick action - drill

chuck

Drill chuck can be fixed by hand.

Workpiece Piece to be drilled or machined. Tool Milling cutter, drill bit, etc.

Version 1.1.4 dated 2015-3-30Page 74 Original operating instructions

BF46 Vario | BF46TCUS

3.3 LIMITED WARRANTY

COMPANY ONE-YEAR LIMITED WARRANTY. COMPANY, MODELS COVERED IN THIS MANUAL, ARE WARRANTED BY COMPANY TO THE ORIGINAL USER AGAINST DEFECTS IN WORKMANSHIP OR MATERIALS UNDER NORMAL USE FOR ONE YEAR AFTER DATE OF PURCHASE. ANY PART WHICH IS DETERMINED TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP AND RETURNED TO AN AUTHORIZED SERVICE LOCATION, AS COMPANY DESIGNATES, SHIPPING COSTS PREPAID, WILL BE, AS THE EXCLUSIVE REMEDY, REPAIRED OR REPLACED AT COMPANY. FOR LIMITED WARRANTY CLAIM PROCEDURES, SEE "PROMPT DISPOSITION" BELOW. THIS LIMITED WARRANTY GIVES PURCHASERS SPECIFIC LEGAL RIGHTS WHICH VARY FROM JURISDICTION TO JURISDICTION.

LIMITATION OF LIABILITY. TO THE EXTENT ALLOWABLE UNDER APPLICABLE LAW, COMPANY LIABILITY FOR CONSEQUENTIAL AND INCIDENTAL DAMAGES IS EXPRESSLY DISCLAIMED. COMPANY LIABILITY IN ALL EVENTS IS LIMITED TO AND SHALL NOT EXCEED THE PURCHASE PRICE PAID.

WARRANTY DISCLAIMER. A DILIGENT EFFORT HAS BEEN MADE TO PROVIDE PRODUCT INFORMATION AND ILLUSTRATE THE PRODUCTS IN THIS LITERATURE ACCURATELY; HOWEVER, SUCH INFORMATION AND ILLUSTRATIONS ARE FOR THE SOLE PURPOSE OF IDENTIFICATION, AND DO NOT EXPRESS OR IMPLY A WARRANTY THAT THE PRODUCTS ARE MERCHANTABLE, OR FIT FOR A PARTICULAR PURPOSE, OR THAT THE PRODUCTS WILL NECESSARILY CONFORM TO THE ILLUSTRATIONS OR DESCRIPTIONS. EXCEPT AS PROVIDED BELOW, NO WARRANTY OR AFFIRMATION OF FACT, EXPRESSED OR IMPLIED, OTHER THAN AS STATED IN THE "LIMITED WARRANTY" ABOVE IS MADE OR AUTHORIZED BY COMPANY.

Technical Advice and Recommendations, Disclaimer. Notwithstanding any past practice or dealings or trade custom, sales shall not include the furnishing of technical advice or assistance or system design. Company assumes no obligations or liability on account of any unauthorized recommendations, opinions or advice as to the choice, installation or use of products.

Product Suitability. Many jurisdictions have codes and regulations governing sales, construction, installation, and/or use of products for certain purposes, which may vary from those in neighboring areas. While attempts are made to assure that company products comply with such codes, company cannot guarantee compliance, and cannot be responsible for how the product is installed or used. Before purchase and use of a product, review the product applications, and all applicable national and local codes and regulations, and be sure that the product, installation, and use will comply with them.

Certain aspects of disclaimers are not applicable to consumer products; e.g., (a) some jurisdictions do not allow the exclusion or limitation of incidental or cons equential damages, so the above limitation or exclusion may not apply to you; (b) also, some jurisdictions do not allow a limitation on how long an implied warranty lasts, consequently the above limitation may not apply to you; and (c) by law, during the per iod of this Limited Warranty, any implied warranties of implied merchantability or fitness for a particular purpose applicable to consumer products purchased by consumers, may not be excluded or otherwise disclaimed.

Prompt Disposition. A good faith effort will be made for prompt correction or other adjustment with respect to any product which proves to be defective within limited warranty. For any product believed to be defective within limited warranty, first write or call dealer from whom the product was purchased. Dealer will give additional directions. If unable to resolve satisfactorily, write to company at address below, giving dealer's name, address, date, and number of dealer's invoice, and describing the nature of the defect. Title and risk of loss pass to buyer on delivery to common carrier. If product was damaged in transit to you, file claim with carrier.

Version 1.1.4 dated 2015-3-30

Page 75

Original operating instructions

BF46 Vario | BF46TCUS

Index

Assembling ........................................................... 21

Available accesories

............................................ 27

Change information .............................................. 74

Changing the speed range

................................... 40

Clamping a tool

BF46TC

........................................................... 37

BF46V

............................................................. 31

Cleaning and lubricating

....................................... 25

Commissioning

..................................................... 25

Control and indicating elements

BF46TC

........................................................... 33

BF46V

............................................................. 28

.............................................................. 73

Drilling-milling capacity ......................................... 17

EC - declaration of conformity .............................. 75

Electrical connection

............................................ 17

Environmental conditions

..................................... 18

Filling in gear oil ................................................... 26

Fine feed

.............................................................. 41

First commissioning

............................................. 25

Lifting equipment .................................................. 15

Load suspension point

......................................... 21

Main switch .......................................................... 13

Malfunctions

......................................................... 72

Misuse

.................................................................... 8

Optional accessories ............................................ 27

Power supply ........................................................ 25

Protective

equipment

....................................................... 14

Protective cover

................................................... 13

Qualification of the staff

Safety

.............................................................. 10

Safety instructions .................................................. 6

Scope of delivery

.................................................. 19

Separating protective equipment

......................... 13

Speed range

......................................................... 40

Speeds

................................................................. 18

Spindle seat

......................................................... 17

Spindle sleeve lever

............................................. 43

Storage and packaging

........................................ 20

Switch on

........................................................ 30, 35

Switching on the machine

.............................. 30, 35

Swivelling the drill-mill head

..................................43

Technical data

Electrical connection

........................................17

Emissions

........................................................18

Environmental conditions

.................................18

Speeds

.............................................................18

Spindle seat

.....................................................17

Technical Details

Drilling-milling capacity

....................................17

Working area

...................................................17

Threading

..............................................................32

Warming up the machine ......................................26

Working area

........................................................17

Palmgren BF 46VARIO, 9680166 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual