Hermle C30 Technical Sheets

Table of ContentsTable of ContentsTable of Contents...............................................................................................................IIIDesignated use................................................................................................................ 1Intended use...................................................................................................................... 2Dry machining and machining with minimum quantity lubrication..................................... 2Qualification....................................................................................................................... 3Troubleshooting................................................................................................................. 4Duty to inform.................................................................................................................... 4Documentation overview................................................................................................... 5Disposal............................................................................................................................. 6Not designated use............................................................................................................ 7General safety regulations.............................................................................................. 9General.............................................................................................................................. 10Operational safety.............................................................................................................. 12Equipment and installation safety...................................................................................... 14Safety during repair work................................................................................................... 15Environmental safety......................................................................................................... 17Gravity-loaded axes........................................................................................................... 18Manual unlocking of the cabin door in case of emergency................................................ 19General technical data.................................................................................................... 21Feed drive.......................................................................................................................... 22Traverse range................................................................................................................... 22Positioning accuracy.......................................................................................................... 22Measuring system.............................................................................................................. 23Lighting.............................................................................................................................. 23Noise level......................................................................................................................... 23Electrical connection.......................................................................................................... 24Electrics machine.............................................................................................................. 25Electrical system internal coolant supply.......................................................................... 25Operating conditions for electrical equipment.................................................................... 26Pneumatic system............................................................................................................. 27Cooling lubricant................................................................................................................ 29Designation of the machine axes....................................................................................... 31Data transfer...................................................................................................................... 32Data backup....................................................................................................................... 32III

Designated useIntended useMachining (according to DIN 8589 part 0) by means of rotating tools with at leastone geometrically defined edge.The following machining operations are possible:• Milling (according to DIN 8589 T3: Face milling, round milling, screw milling, gearhobbing,profile cutting, form cutting)• Drilling (according to DIN 8589 T2: end facing, round drilling, screw drilling, profiledrilling, form drilling)Materials:Metal, wood and plastics. Do not machine materials containing magnesium.Cooling lubricants:No cooling lubricants containing more than 15% by volume of inflammable liquid(e.g. oil).Tools:Use only tools dimensioned and balanced adequately for the speed and metal removingcapacity required (see the manufacturer's specifications and the chapter"Milling spindle").Dry machining andmachining withminimum quantitylubricationAccording to the machining process and the material besides the free-falling swarfalso fine swarf (metallic dust) is produced, which is not bound or discharged by acooling lubricant. When the amount of swarf is large, it must be extracted via a specialworking area extraction and must be separated by means of a filter.In the light alloy processing (e.g. aluminium) with a very large amount of fine swarfbeing produced, also a possible exothermal reaction has to be taken into account.In this case, appropriate fire protection and explosion prevention must necessarilybe provided. In any case a swarf accumulation in the working area of the machiningcentre should be avoided (clean the working area within suitable intervals).Examples of inflammable and explosive materials:• Organic, natural dust from coal and wood• Inorganic dust from magnesium, aluminium, or zinc

Designated useTroubleshootingReport any irregularities, noise and obvious faults to your superior and note them inthe workbook. In case of danger, shut down the machine immediately (press EmergencyStop device).Duty to informBefore putting the machine into operation, the owner has to make sure that theoperating manual was read and understood by the relevant personnel. In addition,the general accident prevention regulations of the relevant professional associationmust be heeded.

Designated useDisposalAt the end of their service life, the individual components (consumables and subassemblies)of the machine must be passed on to the appropriate recycling process.If recycling is not possible, the disposal of the components (consumables andsubassemblies) must be carried in accordance with the regulations of the country inquestion and in accordance with regional or local provisions.Proper disposal of the components (operating materials and assemblies) does notcause any hazards to people or damage to the environment. We recommend you tocontact a company specialized in waste disposal.

ChapterGeneral safety regulations

General safety regulationsGeneralThis machine has been built according to the state-of-the-art technology and to thecurrent safety regulations. Provided that it is operated properly, no specific dangersfor the operator are to be expected.It is assumed that the operating personnel is adequately trained in the operation ofmachine tools.!WarningWhen operating the machine, wrong handling can result in serious injuries thatmay become fatal.For this reason, please heed the following instructions:• When working with the machine, for the sake of your own safety, wear thenecessary personal safety equipment including safety boots, safety goggles,protective clothing and safety gloves, etc., as well as close fitting work clothesand hair protection for long hair. Roll up sleeves towards the inside only. Takeoff wrist watches, rings, chains and similar jewellery before starting work!• If the noise level is high, wear hearing protection!• To keep the noise level of the machine to a minimum, you must monitor thenoise emission directly on-site during machining. If noise emission exceeds thelegally determined limits, inform your supervisor.• Always ensure sufficient ventilation and aeration.• Clean off any spilled liquids (cooling lubricant, grease or oil) immediately afterspilling due to risk of slipping!• At the work place, the MAC limit value of the total concentration of oil vapour andoil aerosol of 10 mg/m 3 must be observed! Therefore always ensure sufficientventilation and aeration! If necessary, have the relevant controlling authority(e.g. professional association) carry out a measurement. If the limit is exceeded,change process conditions and/or have an extractor installed!• After switching off the machine by means of the main switch the socket at theswitch cabinet is still alive!10

General safety regulations• If the owner of the machine performs modifications on the machine - this appliesespecially to later additions of foreign additional units, modifications of the controlconcepts or even modifications of protective devices - these changes must beagreed upon with Hermle AG! In the absence of such agreement, Hermle AGwill not be liable for any damage which may occur as a result thereof!• Operate the machine only when it is in flawless and reliable condition. Eliminateany defects that occur immediately!• All safety and warning signs on the machine must be complete and fully legibleat all times!• The operator must provide appropriate instructions and monitoring to ensure thatthe work area around the machine and the area around it are clean and tidy!• Read the accident prevention regulations of your controlling authority (e.g.Employer's Liability Insurance Association)! If these regulations are not displayedat your work place, please inform the person in your company responsible forsafety!11

General safety regulationsOperational safety!WarningWhen operating the machine, wrong handling can result in serious injuries thatmay become fatal.For this reason, please heed the following instructions:• As long as the machine is working, do not reach into the area of rotating shafts,equipment or tools!• The protective cabin must always be closed completely during operation andmay not be opened!• Use only tools which are suitable for machining the respective material. Pleasealso note that some tools are only allowed for certain rpm ranges and are subjectto wear.• The use of grinding wheels and cutting-off wheels is not allowed!• When working in an area with rotating tools, do not wear protective gloves – riskof the hand being caught in the rotating tool!• Work pieces and mounting devices may only be handled using appropriateloading devices!• Lifting tackles and loading devices, which are used to load the machine, mustbe adequate for the purpose and provide sufficient lifting capacity!• It is recommended to install an extraction system when machining graphite ormaterials the machining of which produces fine dust!• Each time before setup, remove the tool from the spindle and make certain that allfastening screws (for example clamping devices, etc.) are securely tightened!• Do not reach between milling spindle and work piece.• Ensure correct and safe clamping of the work pieces.• The work piece has to be securely mounted and/or clamped with adequateclamping devices!12

General safety regulations• No screws, nuts or similar parts must protrude from the clamped tool. Specialcare must be taken when using far jutting out boring heads or similar objects!• Always wear adequate protective clothing and safety goggles during the setupmode!• The machining of readily flammable, explosive materials (e.g. magnesium) isnot allowed!• The machine operator has to ensure that clamping devices and work piecesare clamped correctly!• A manless test run of a new program is strictly prohibited!• To avoid any evaporation during machining, ensure sufficient cooling lubricantor choose a dry machining method!• Always select milling work in such a manner that no cooling lubricant can splashout of the protective cabin.• Change tools on time before they become blunt and are then at risk to fracture.• When changing tools, observe the permissible rpm speed! Danger producedby entering the wrong rpm speed (bouncing error during input via keyboard),large-sized tools or special tools could thus erroneously be operated up to thepossible maximum spindle speed.• Use only safety goggles marked CE (safety goggles according to EN 166 witheye-protecting lenses made of polycarbonate)! Observe the exchange intervalsof the eye-protecting lenses.• You must wear safety goggles when working with the cabin open!• The use of cooling lubricants containing more than 15% by volume of inflammableliquid (e.g. oil) is not admissible!• For the operation, refer inter alia to the technical documents of the ancillaryequipment which are enclosed in the "Machine documentation" folder!13

General safety regulationsEquipment and installationsafety!WarningWhen operating the machine, incorrect handling of the equipment and systemscan result in serious or fatal injuries.For this reason, please heed the following instructions:• Before starting work, make sure that all safety devices of your machine are workingproperly, particularly the locking and switching functions of the door securityswitches, and that all enclosure parts are present and properly fastened!• Protective cabin, protective devices, cover plates etc. may only be removed forservicing work (exchanging parts, repairs)! The machine must not be startedwithout these features!• Safety devices must never be manipulated, switched off or in any other wayby-passed.• Before performing any work on hydraulic systems, these systems must alwaysbe depressurized via the pressure venting valve. The pressure must be checkedvia the manometer. It is not sufficient to switch off the hydraulic systems .• It is prohibited to bypass or to manipulate the safety switch of the cabin locks.14

General safety regulationsRepair• If at all possible, repair work should be carried out with the machine at standstill.If this is not possible, special organizational and personal measures mustbe taken. e.g. The necessary work may only be carried out by trained personswho are capable of averting possible risks, that is, repair work (replacing parts,repair) may only by carried out by who by virtue of their technical knowledgecan execute the work competently, carefully and completely and have especiallybeen trained by Hermle AG.• A particular risk potential is encountered in repair work (replacing parts, repairs).The servicing personnel is at a particularly high risk – for example when:––––––Working under difficult environmental conditions (e.g. not enough room,forced posture, unsafe standing position)Working with the protective devices turned offImprovising during troubleshooting (unscheduled servicing)Troubleshooting with the machine runningUnintentional machine movementsWorking with different media (e.g. hydraulics, pneumatics, electricity)• During repair work, it is possible that some protective equipment will be removedor disabled. In these cases, especially qualified personnel capable of recognizingthe risks which may occur and of avoiding accidents and damage must behired to carry out this work.• When working on devices that are electrically charged, it is obligatory to have anadditional qualified person present that can intervene in case of emergency!• It is absolutely necessary to observe the notes and regulations in the serviceinstructions of Hermle AG!• Lifting tackle (crane, ropes, etc.) must be provided for repair work capable of transportinga minimum load of 500 kg (to be able to move the entire machine).16

General safety regulations!CautionEnvironmentalsafetyImproper disposal of the machine components (operating materials and assemblies)can cause hazards to people and damage to the environment.For this reason, please heed the following instructions:• Select oils and cooling lubricants according to their environmental compatibilityand look for a supplier who takes care of their proper disposal!• Dispose of waste oil, cooling lubricants, dirty filter elements, oily swarf etc. in anenvironmentally responsible manner! We recommend you to contact a companyspecialized in waste disposal.• At the end of their service life, the individual components (consumables andsubassemblies) of the machine must be passed on to the appropriate recyclingprocess. If recycling is not possible, the disposal of the components (consumablesand subassemblies) must be carried in accordance with the regulations ofthe country in question and in accordance with regional or local provisions.• In any case, observe the state regulations on environmental protection.17

General safety regulationsGravity-loaded axesGravity-loaded axes are axes that can execute unintended, dangerous movementsdue to the force of gravity as the result of a malfunction or incorrect action.The following gravity-loaded axes are present on the machine:C-Series / B 300:Z slide (spindle slide)A-axis (swivelling rotary table)C-axis (table plate)Lifting axis (pallet changer)!DangerWhen carrying out servicing work (maintenance, inspection, repair) on gravityloadedaxes, unintended, dangerous machine movements can result in seriousinjuries that may become fatal!For this reason, please heed the following instructions:• Switch off the machine at the main switch and secure the main switch with apadlock against inadvertent switching-on!• Support the axis securely or move/pivot the axis into a safe position.• Attaching the axis to a crane is permitted only after receiving approval from asupervisor.18

General safety regulationsC series: Position of the unlocking switchManual unlockingof the cabin door incase of emergencyAB 300: Position of the unlocking switchAIn case of emergency, the cabin door of the machine can be manually unlocked fromthe outside by means of an auxiliary unlocking device. The auxiliary unlocking deviceis on the top of the cabin door [A].Procedure:• Unscrew locking screw [1] on the unlocking switch.• Turn unlocking screw [2] on the unlocking switch about 1/2 turn toward the rightuntil the cabin door is unlocked.• Once the cabin door has been unlocked, turn the unlocking screw [2] back intoits initial position (recess pointing upwards – see graphic below) and tighten thelocking screw [1] again.Unlocking switch:1 219

20General safety regulations

ChapterGeneral technical data21

General technical dataFeed driveStandardFeed force 7000 NRapid traverse 45 m/minAcceleration 6 m/s 2Diameter and pitch of the feed spindles:X-axisY axis (C 30)Y axis (C 40)Z axis40 / 15 mm50 / 25 mm50 / 40 mm40 / 25 mmDynamicFeed force 8500 NRapid traverse 60 m/minAcceleration 10 m/s 2Diameter and pitch of the feed spindles:X-axisY-axisZ axis40 / 20 mm50 / 40 mm40 / 30 mmTraverse rangeC 30X-axisY-axisZ-axis650 mm600 mm500 mmC 40X-axisY-axisZ-axis850 mm700 mm500 mmPositioning accuracyPositional toleranceTp in X-Y-Z axes according to VDI/DGQ 34410.008 mmIn order to be able to maintain the positioning accuracy over the entire duration ofuse, the ambient temperature should be continuously 20 °C +/- 1 °C (68 °F).22

General technical dataDirect measurement X/Y/ZResolution 0.1 µInput sensitivity 0.1 µDisplay step 0.1 µMeasuring systemMachine lighting2 halogen lamps > 500 luxLightingMachine-specific noise emission parameters according to EN ISO 3746Noise levelOperation under load (machining)Corrected* ) average acoustic pressure level of measuring areaUncertaintySound power levelUncertaintyL pA= 78 dB (A)K pA= 4 dB (A)L WA= 98 dB (A)K WA= 4 dB (A)*) A correction for external noise and the environment / room is includedIn order to estimate the noise pollution at the work place (acoustic emissions) derivedfrom the acoustic emission specifications of the machine, it is necessary to considerthe sound wave reflections, the actual operating conditions at hand and the influenceof the noise emissions of surrounding machines.In any event, the machine operator must take into consideration the Accident PreventionRegulations for noise (BGV B3).According to BGV B3 § 5 – valid for working areas: If risk of damage to hearing resultingfrom noise exists or is anticipated for the insured, the proprietor is obligatedto arrange the working areas in such a way as to minimize the propagation of soundwaves, using practical experience in applying the latest sound minimizing technology.23

General technical dataElectrical connectionConnection conditionsThe machine is equipped with a frequency-controlled converter system. This systemmay be connected only to earthed networks TN-S and TN-C (VDE 0100 part 300)with a nominal voltage of 3 AC 400 V.If the mains voltage differs an autotransformer can be connected in series. If thenetwork structure differs from the previously described TN-S and TN-C, an isolationtransformer with a secondary side star point must be provided or requested.The choice of the cross section of the line to be used for connection to the mainsshould be made according to the connection conditions laid down in the electricalcircuit diagram. The electrical circuit diagram is to be found in the compartment onthe inside of the switch cabinet.The direction of the rotating field must be clockwise. Before switching on the machine,the direction of the rotating field must be tested with a measuring device. If necessary,alter the direction of rotation by interchanging 2 phases (e.g. L1 and L2).System short-circuit capacityThe converters are set to sinusoidal current operation. The minimum system shortcircuitcapacity (SK network) at the connecting point of the machine must complywith the following data:C 30 with control unit iTNC 5302.15 MVAC 30 with control unit S 840 D2.50 MVAC 402.50 MVAImportantAn insufficient system short-circuit capacity can result in converter failures as wellas in failures and damages of other devices which are connected at the same mainsconnecting point as the converter.Fault current protective devicesWhen connecting the machine to the mains with an earth-leakage circuit-breaker,make sure to use selective universal-current sensitive circuit-breakers according tothe requirements DIN EN 50178.For instance an earth-leakage circuit-breaker from Siemens with 63 A and the designation:––5SZ6468-0KG00 (without auxiliary switch)5SZ6468-0KG30 (with auxiliary switch)24

General technical dataMachine connection dataMains connection (ICS)400 V +/- 10 % / 3 PH / 50 HzControl voltage24 V DCFuses63 ALine diameter 16 mm 2Electrics machineTotal connected load of the machineFor C 30 U / C 40 U with standard feed drive:Total connected loadmax. 41 KVAFor C 30 U / C 40 U with dynamic feed drive:Total connected loadmax. 43 KVAFor C 30 V / C 40 V with standard feed drive:Total connected loadmax. 27 KVAFor C 30 V / C 40 V with dynamic feed drive:Total connected loadmax. 29 KVAThe total connected loads stated refer to a machine equipped with all possible options(e.g. swarf conveyor, additional magazine, pallet changer); accordingly theloads given are maximum values.Connection data for internal coolant supplyMains connection (ICS)400 V +/- 10 % / 3 PH / 50 HzControl voltage24 V DCfuses50 ALine diameter 10 mm 2Electrical systeminternal coolantsupplyTotal connected load of the internal coolant supplyTotal connected loadmax. 16.6 KVAImportantThe internal coolant supply must be connected to the same 400 V power supply asthe machine but with separate fuses to avoid a possible power failure to the internalcoolant supply while the machine is running.25

General technical dataOperating conditionsfor electricalequipmentOperating conditions for electrical equipment (according to EN 60204-0)Room temperatureMinimum ambient temperature + 5 °CMaximum ambient temperature+ 40 CRelative humidityMaximum relative humidity at maximum ambient temperature* ) 50%* ) higher relative humidities may be allowed at lower temperatures (e.g. 90% at 20 °C)26

General technical dataCompressed air connectionConnection pressurep >/= 6.0 barPneumatic systemCompressed air supply lineWhen connecting your in-house supply to the machine, make sure that the connectionis effected by means of a flexible pneumatic hose (internal diameter 11 mm andexternal diameter 16 mm) and a quick-acting gate coupling (nominal width 7).Compressed air grade (according to ISO 8573-1)The quality of the compressed air provided must meet the following conditions:• Residual dust (class 4)ClassMaximum number of particles / m 3 (particle size "d" (µm))0.1 < d < / = 0.5 0,5 < d < / = 1 1 < d < / = 54 100000 1000 10• Residual moisture (class 4)Class 4 < 6 g / m 3• Residual oil (class 4)Class 4 < / = 0.01 mg / m 3• Pressure dew point (class 4)Class 4 < / = 3 °C (5,4 F)If the machine is, however, additionally equipped with sealing air for glass scales(option) in order to obtain extremely high precision, it must be guaranteed thatthere are no large differences in temperature between the supplied sealing airand the ambient temperature of the installation site.ImportantIf the grade of the supplied compressed air does not meet the conditions listed above,the service lives of the machine filters cannot be guaranteed. This may result in amalfunction of the measurement system (glass scales)!27

General technical dataBasic consumption valueStandard machine120 slpmThe consumption of compressed air is calculated on the basis of 3 tool changes perminute.Optional consumption valuesSealing air for spindleSealing air for glass scalesSealing air for tool measurementSealing air for C-axisSealing air for A-axisExternal blast airBlast air for spindle centreSpindle 28000 rpmSpindle 40 000 rpmMinimum quantity lubrication (Unilube), externalMinimum quantity lubrication (TKM), internalPallet changer PW 160 (max. 2 pallet changes / min)Pallet changer PW 800 (max. 2 pallet changes / min)ZM 43 (max. 5 tool transports / min)ZM 87 (max. 6 tool transports / min)ZM 157 (no information necessary due to minimal consumption)+ 25 slpm+ 20 slpm+ 10 slpm+ 35 slpm+ 90 slpm+ 660 slpm+600 slpm255 slpm+ 255 slpm+ max. 80 slpm+ max. 200 slpm+ 220 slpm+ 330 slpm+ 30 slpm+ 24 slpmCalculation of the individual consumption values(120 slpm + "X" slpm) x 1013 mbar x 293 KV 1 B=273 K x 6000 mbar= "X" litres/min(at 6 bar operatingpressure)"X" slpm = Sum of optional consumption values28

General technical dataSelection of cooling lubricantCooling lubricantNoteHermle AG cannot be held liable for any damage to the machine caused by inappropriatecooling lubricant or insufficient, incorrect maintenance of the cooling lubricantby the owner of the machine.Due to the fact that the wide range of machining processes may also lead to differentcooling lubricants being used, Hermle AG cannot recommend any special kindof cooling lubricant. Depending on the corresponding application, the owner of themachine should select the cooling lubricant most suited to his machining processwith his cooling lubricant supplier.On the basis of their extensive volume of data, well known cooling lubricant manufacturerscan supply, in most cases without problems a certificate of use. This meansthat proof can be provided as to which cooling lubricants have been in use with whichmachine types and for how long.29

General technical dataThe basic requirements listed below should, however, always be considered whenchoosing a cooling lubricant:• Suitable for the planned machining processes and usable for the widest possiblerange of applications.• Suitable for the material being processed.• Suitable for both roughing and finishing.• Readily miscible with water (emulsions).• Offering protection against corrosion at appropriate concentrations.• Good metal removing capacity and little foaming.• Environmentally friendly - disposal by the supplier.• The cooling lubricant cannot be mixed with oil from leaks. Leak oil, which undercertain circumstances may get into the cooling lubricant, must not be absorbedby the latter but it should float on its surface.• The cooling lubricant emulsion may not contain more than 15 vol. % of flammableliquid (e.g. oil).• The cooling lubricant concentrate must not be affected by bacteria or by fungi and,if made up according to the instructions, not irritate the skin. Request appraisalsof skin compatibility.• Cooling lubricants must be designed so that no seals, elastomers, machine paintor machine parts are affected by them.This is usually guaranteed in the case of cooling lubricants containing mineral oil.In the case of mineral-oil-free or semi-synthetic cooling lubricants, for exampleester-based products, this must be proven in each individual case. If ester-basedcooling lubricants are used, it is essential to consult the respective cooling lubricantmanufacturer.• The cooling lubricant must be well filterable and separable.• To prevent various chemical reactions on the machine, the cooling lubricant emulsionshould be obtained from the same manufacturer as the operating lubricantsused in the machine.Filling amountFilling amount without internal coolant supplyC 30C 40Filling amount with internal coolant supplyC 30C 40240 litres350 litres1190 litres1300 litres30

General technical data3 axesDesignation of themachine axesZ +Y +X +4 / 5 axesZ +C +Y +A +X +31

General technical dataData transferThere are connecting sockets on the right-hand side of the switch cabinet for thedata input and output.• Socket V 24 - RS 232-C (only for machines with Heidenhain Control)• Ethernet 10/100 Base T (to 100 MBits/s; depending on the network load), RJ 45connection possibilityThe configuration of the pins of both interfaces is given in the circuit diagram of themachine.Data backupTo guard against a certain data loss, a CD is enclosed in the side pocket of theswitch cabinet when the machine is delivered. This CD contains a backup of variousmachine data of operational significance. Be sure to make a backup copy and keepit in a safe place!32

ChapterTransport and installation33

Transport and installationGeneral transportregulations!DangerA sliding load during transport with a transport vehicle (including in road traffic) canresult in serious or even fatal injuries to the transport personnel and any personsthat may be present.Because of this, the forwarding company or transporter must observe the followingcautions:• Special caution and care must be employed at all times to exclude dangers forpersons!• The means of transport must meet the requirements of the highway code andlicensing regulations!• The dimensions and permissible total weight / carrying capacity of the transportvehicle must be approved for the machine in question (including packagingand transport device)! This means for example observing the permissible totalweight of the transport vehicle, the capacity of the loading surface for receivingloads, and the required loading width / loading height / loading length (e.g. useflatbed trailer)!• The transport vehicle / transport surfaces must be air-cushioned!• The transport vehicle must be equipped with an extendable tarp and frame - i.e.a so-called "Curtainsider, Edscha or Hamburg covering" (no throw-over tarpsthat rest on the machine)! To prevent friction-related damage caused by thetarp, the load must be protected (e.g. by bubble wrap).• Anchor points must be present on the transport vehicle according to DINEN 12640 with a rating of at least 20 kN (2000 daN) of load!• Tension belts / lashing chains in flawless condition according to DIN EN 12195-2(for tension belts) or DIN EN 12195-3 (for lashing chains) must be provided witha load capacity of at least 2000 daN! The number of tension belts depends onthe number of items to be loaded. For the machine alone, at least 4 belts arerequired. For the machine with additional magazine, pallet changer and accessories,at least 16 belts are required in total.• The anchor points and lashing equipment must be in perfect condition from asafety perspective.• Tested anti-slip mats (coefficient of friction at least µ = 0.6) must be used.• To continue, see the following page.34

Transport and installation• The transport surface must be clean, free of grease and ice (e.g. no nails, oil,grease, sand, or other residue)!• Rubber mats must be placed at points where the clamping devices rest onmachine components or transport devices for protection between the clampingdevice or transport device and the machine component, to prevent damage tothe clamping device and the machine.!DangerA sliding load during transport by rail, ship, or air can result in serious or even fatalinjuries to the transport personnel and any persons that may be present.Because of this, make certain the machine is properly secured for the transportvehicle being used!The clamping and screen forces must be calculated by a specialist company forthe specific transport type and the machine protection designed accordingly, asall of the transport information listed in this section only applies for transport usinga transport vehicle (truck).35

Transport and installationGeneral safety instructions!DangerWhen transporting and installing the machine, suspended loads or wrong handlingcan result in serious injuries or death.For this reason, please heed the following instructions:• People must never be allowed to stand under heavy loads!• The installation of the machine may only be performed by sufficiently qualifiedpersonnel, and commissioning of the machine only by the Hermle AG CustomerService or a service authorized by Hermle AG.• Only use means of transport (fork lift trucks, lifting trucks, cranes, heavy loadrollers etc.) with sufficient lifting power, i.e. more than the indicated transportweight!• When selecting the lifting tackle (straps, chains, ropes etc.), make absolutelysure that their maximum load capacity is sufficient to lift the transport weightof the machine! The maximum load capacity of a lifting tackle is usually clearlymarked.• Affix your lifting tackles only to the HERMLE lifting devices provided for thispurpose!• Before unloading the machine, make sure that there are no loose part(e.g. machine components, straps) on the transport pallet!• Lift and put down the machine only vertically, steadily, and without jerky movements!• Keep unauthorized persons outside of the danger area during machine installationand commissioning!!WarningIn case of fire, blocked escape and rescue routes can result in danger to life.For this reason, when installing the machine, please note that if there is an escaperoute to both sides, an open door must always be taken into consideration! Thisis why a minimum clear passageway of 500 mm around the entire machine mustbe maintained and increased by the door width in the door area!36

Transport and installation!DangerInformation on thetransport in a packingcaseWhen transporting the machine in a packing case, suspended loads or wronghandling can result in serious injuries or death.For this reason, please heed the following instructions:• People must never be allowed to stand under heavy loads!• During machine transport, keep unauthorized persons out of the danger area!• The symbols (according to ISO R/780) written on the packing case must beobserved as handling instructions!• Only use fork lift trucks and other lifting trucks with sufficient lifting power, i.e.capable of carrying more than the transport weight indicated on the packingcase (gross weight)!• Before lifting the packing case, note the centre of gravity and align your meansof transport and lifting tackle accordingly! The centre of gravity is indicated onthe packing case by a suitable symbol.• When selecting the lifting tackle (straps, ropes chains, crane cross-beams, etc.),make absolutely certain that their maximum load capacity is sufficient to lift thetransport weight (gross weight) of the packing case. The maximum load capacityof a lifting tackle is usually clearly marked.• Attach the lifting tackle (straps, ropes, chains, etc.) only to the lifting pointsprovided for this purpose and in the required angular position! The lifting pointsare indicated along with the required angular position of the lifting tackle on thepacking case by suitable symbols.• Make sure that the weight is evenly distributed to all lifting tackles!• Use a crane cross-beam suited to this purpose!• During transport by fork lift truck, only drive into the openings provided for thispurpose at the case bottom! Guide the forks far enough into the openings sothere is no possibility the packing case could fall over! Watch out for centre ofgravity of the packing case!37

Transport and installation• Lift and put down packing case only vertically, evenly and without jerky movements!• Only qualified shipping companies are permitted to transport the machine in apacking case.Important• When selecting a means of shipping equipment and lifting tackles, note the weightand dimensions of the packing case! You will be informed of the weight and dimensionprior to the delivery of the machine.• Be sure not to damage the machine during unpacking! Unpack the machine andits components carefully, check whether the delivered goods are complete andinspect them for possible damage during transport. Should any damage be detected,please notify the HERMLE AG Service Department at once!• After removing the packing case, please observe the information of these transportinstructions!38

Transport and installationDefinition of the symbols used on the packing caseFragile goodsThe packing case must be handled with care and under no circumstancestoppled or tied with strings!TopThe packing case must always be transported, handled and storedin such a way that the arrows always point upwards. Excessivetilting or turning over is prohibited!Attach hereThis symbol indicates to which point and in which angular positionof the packing case the lifting tackle (straps, ropes, chains, etc.)must be attached. If the packing case does not hang horizontally,the lifting tackle must be adjusted accordingly on one side!Protect from moistureThe packing case must be protected from excessively high humidityat any time. This means that it must be stored in closed rooms!Centre of gravityThis symbol indicates the position of the centre of gravity, whichmust be observed under all circumstance when lifting it by craneor fork lift truck!Do not place the forks hereThis symbol is only attached to the sides of the packing case whichmay not be lifted using the fork lift truck. If this symbol is missing,lifting is allowed.39

Transport and installationC 30 TransportweightTransport weight of the standard machine without accessory equipment:C 30approx. 9200 kgC 30 TransportdimensionsTransport dimensions of the standard machine without accessory equipment:2640 (with detached Z motor and energy chain)2743 (with dismounted Z motor)2892 (with standard transport / deliver condition)2214315440

Transport and installationImportantC 30 Transport centreof gravityWhen transporting the machine, make certain to note where the centre of gravityis and to arrange the transporting equipment and lifting tackles accordingly! Thetransport centre of gravity is identified on the machine / shipping package by thefollowing symbol.Rear view1701206345Side view120675441

Transport and installationC 40Transport weightTransport weight of the standard machine without accessory equipment:C 40approx. 10300 kgC 40Transport dimensionsTransport dimensions of the standard machine without accessory equipment:2640 (with detached Z motor and energy chain)2743 (with dismounted Z motor)2892 (with standard transport / deliver condition)2354315442

Transport and installationImportantWhen transporting the machine, make certain to note where the centre of gravityis and to arrange the transporting equipment and lifting tackles accordingly! Thetransport centre of gravity is identified on the machine / shipping package by thefollowing symbol.C 40Transport centre ofgravityRear view1701139295Side view113989743

Transport and installationAnchor points forsecuring the load112 2!DangerA sliding load during transport (including in road traffic) can result in serious or evenfatal injuries to the transport personnel and any persons that may be present.For this reason, please make sure that the machine is secured correctly!The available anchor points for securing the machine when loading are 2 lifting eyesin the interior of the machine [1] at the front of the machine and 2 lifting eyes on themachine bed [2] at the rear of the machine.44

Transport and installation!CautionTransport informationWhen removing the transport device, damage can be caused to the machine ifsensitive machine components, e.g. guides, scales or lines are stepped on. Steppingon these sensitive machine components should therefore be avoided.• A suitable crane is always needed to lift the machine from the transport pallet!More detailed information can be found in the section "Transport by crane".• The forwarding company has to provide the crane cross-beam, but these devicescan also be borrowed from Hermle AG for a fee.• The switch cabinet of the machine is screwed down to the machine during transportationand must be detached prior to being put into operation.• Please return the transport aids (transport device, heavy load rollers, etc.) afterthe machine has been commissioned.45

Transport and installationStorage information• The machine is delivered in a preserved state and can be stored at a closed, drylocation for up to 6 months. If the intended time of storage is longer, a suitablelong-term preservation is required (HERMLE AG must be consulted about this).• If the machine is stored correctly, its properties will remain unchanged. Underunfavorable storage conditions and if the machine is stored incorrectly, its propertieswill be adversely affected. These changes may be caused, for example, byextreme variations in temperature or humidity.ImportantHumid storage rooms of more than 65% of relative humidity and a variable ambienttemperature are unsuitable. Make sure that no condensation takes place.46

Transport and installationNoteTo ensure problem-free and safe installation of the machine, in addition tolong-term machining precision, please make the following preparations relatedto the machine location:Preparations relatedto the machine location• Determine the machine location and space requiredDetermine a location for the machine. As you do this, note the following:– Take into consideration the dimensions of the machine. The machine dimensionscan be found in the chapter entitled "Machine dimensions and weight"!– Please note that in the direction of escape you must always factor in an opendoor on both sides! This is why a minimum clear passageway of 500 mmaround the entire machine must be maintained and increased by the doorwidth in the door area!– Make certain in addition there is good accessibility to operate and maintainthe machine, sufficient free space to move around in and adequate room forthe machine operator.– Eliminate or identify areas with risk of tripping or other dangers!• Check the transport route to the machine locationDetermine a transport route to the location where the machine will be installed. Indoing so note among other things:– Door openings– Overhead clearances– Areas to move off to the side– Other obstructions (for example building supports)– The nature of the surface (in terms of transport on heavy load rollers)– Ascending and descending routes– Carrying capacity and size of elevatorsIf the transport dimensions of the machine, with a standard transport, are too largefor your facilities, please contact the Hermle company!47

Transport and installation• Check the quality of the machine locationPlease note that the quality of the machine location has a significant effect on themachining precision of the machine. Consistently high machining precision canonly be achieved by observing the following requirements:––––––Set the machine up on a concrete base plateMinimum quality: B 25 reinforced, thickness > 200 mmConcrete base plate on a natural soil base(subsurface sufficiently compacted)Every precision pad for the machining centre can correct 0.5 mm of unevennessin the floor at its supporting surface.Make certain there is a constant power supply with a maximum permissibledeviation of +10% / -10%.Avoid surface vibrations caused by nearby machines and/or fork lift trucktraffic that affect the machine location.Provide adequate lighting conditions in the area of the machine's location.To achieve optimal protection against slipping, make certain the installationsurface in general and in particular the support surfaces for the precisionpads are free of dirt, grease, and oil. Always clean them with a solvent suchas acetone.When installing the machine on top of the ceiling or bearing construction, a certainamount of yield and bend must be assumed for the floor beams. This couldcause a breakthrough in the ceiling or bearing construction and could also have anegative effect on machining precision. The following requirements must thereforeurgently be observed:– Make certain the weight and weighted forces of the machine are safely containedby the bearing constructions and have a structural engineer provideproof of sufficient carrying capacity.– If at all possible, do not place the machine near the middle of beams(where the deflection of the beam is greatest). Instead place it close towhere there is a support.48

Transport and installation• Check the floor of the machine location to ensure that oil cannot leakthroughThe oils, greases and cooling lubricants used by the machine are water pollutants.Because of this, environmental protection requirements must be taken intoconsideration and observed. These polluting substances must not get into watersources, into the ground or into the sewer system. Planning and installation mustbe done with special care, especially in water protection areas and areas close tostreams, rivers or lakes. Therefore, please observe the following requirement:– The base of the machine location must be sealed and resistant to all materialsused in the machine (oil-proof base without expansion joint).If there is no way to guarantee this condition, the machine must be installed inan adequate waterproof collecting pan. Please note that the collecting pan mustmeet special requirements related to the machine installation. In this event, get intouch with the Hermle AG if required. Please observe the following requirementswhen designing the collecting pan:– The collecting pan must have a recess in the area of the machine legs sothat the precision pads rest directly on the even floor surface and not on thecollecting pan. Danger of the machine slipping!– The machine and swarf conveyor must be placed higher to compensate forthe dimension of the collecting pan.– The collecting pan must not have a negative effect on the evenness of theinstallation surface.– The recess for the machine leg in question must be designed to ensure theadjusting screw of the precision pad is accessible.Collecting pan withrecessMachine leg> 200 mmAdjusting screwPrecision padBase plateConcrete B 25, reinforced49

Transport and installation• Check the climatic conditions at the machine locationPlease note that the climatic conditions at the machine location have a significanteffect on the machining precision of the machine. Consistently high machiningprecision can only be achieved by observing the following requirements:––––Maintain a constant ambient temperature of approximately 20 °C +/- 1 °C(68 °F +/- 1.8 °F).Avoid local heating up and cooling off on the machine, for example causedby direct sunlight, heated bodies or draughts of air, etc.Keep the relative humidity continuously under 65%.For extremely high precision requirements, place the machine in an air-conditionedroom.Preconditions forcommissioningNotePreconditions for an exact geometrical acceptance check during commissioning:• Moment for start of operationsThe time of commissioning must be selected such that the machine will have stayedat the installation site on its precision pads for 72 hours before the geometricalacceptance check (last step of commissioning) is made!• Ambient temperatureThe machine must have stayed in a constant ambient temperature of approx.20 °C +/- 1 °C (68 °F +/- 1.8 °F) for 72 hours, before the geometrical acceptancecheck is carried out!50

Transport and installationNotePreparations forcommissioningTo ensure problem-free and reliable machine commissioning by Hermle CustomerService, please make the following preparations:• Floor evenness at machine locationMeasure the evenness of the floor in the area where the machine will be installedaccording to the "Dimension sheet on floor evenness at the machine location".Please fill in the dimension sheet and send it back to Hermle AG prior to the planneddelivery of the machine. Should the completed dimension sheet of the Hermle AGnot be available when the machine is delivered, the Hermle Service Departmentwill assume optimum floor evenness during the commissioning of the machine.Hermle AG reserves the right to invoice additional costs that may be incurred dueto missing information related to the floor evenness.• Maintenance and service areaPlease ensure that the machine is easily accessible from all sides for maintenanceand service work. Observe, depending on the equipment of the machine, the pulloutdimension (see item Machine dimensions in chapter "Machine dimensionsand weight") of the swarf drawer or the swarf conveyor.• PositioningPlace the machine on the precision pads at its intended installation site and observethe instructions in the following chapter "Arrangement of the precision pads" andin the subsequent transport chapters.• Pneumatic connectionPrepare a pneumatic connection for the machine and make the connection.When making the pneumatic connection from the machine to your in-house connection,observe the instructions in the following chapter "Pneumatic connection"and the instructions in the chapter "General technical data".• Electrical connectionPrepare an electrical connection for the machine and a separate electrical connectionfor the internal coolant supply (optional). Make these connections.When making the electrical connection from the machine to your in-house connection,observe the instructions in the following chapter "Electrical connection"and the instructions in the chapter "General technical data".• Cooling lubricantHave a suitable cooling lubricant available. Note the instructions in the chapter"General technical data".51

Transport and installationElectrical connectionConnection conditionsThe machine is equipped with a frequency-controlled converter system. This systemmay be connected only to earthed networks TN‐S and TN‐C (VDE 0100 part 300)with a nominal voltage of 3 AC 400 V.If the mains voltage differs an autotransformer can be connected in series. If thenetwork structure differs from the previously described TN‐S and TN‐C, an isolationtransformer with a secondary side star point must be provided or requested.The choice of the cross section of the line to be used for connection to the mainsshould be made according to the connection conditions laid down in the electricalcircuit diagram. The electrical circuit diagram is to be found in the compartment onthe inside of the switch cabinet.The direction of the rotating field must be clockwise. Before switching on the machine,the direction of the rotating field must be tested with a measuring device. If necessary,alter the direction of rotation by interchanging 2 phases (e.g. L1 and L2).System short-circuit capacityThe converters are set to sinusoidal current operation. The minimum system shortcircuitcapacity (SK network) at the connecting point of the machine must complywith the following data:C 30 with control unit iTNC 530 2.15 MVAC 30 with control unit S 840 D 2.50 MVAC 40 2.50 MVAImportantAn insufficient system short-circuit capacity can result in converter failures as wellas in failures and damages of other devices which are connected at the same mainsconnecting point as the converter.Fault current protective devicesWhen connecting the machine to the mains with an earth-leakage circuit-breaker,make sure to use selective universal-current sensitive circuit-breakers according tothe requirements DIN EN 50178.For instance an earth-leakage circuit-breaker from Siemens with 63 A and the designation:––5SZ6468-0KG00 (without auxiliary switch)5SZ6468-0KG30 (with auxiliary switch)52

Transport and installationAGraphic 2Graphic 1L1L2L3NPEMains phaseMains phaseMains phaseZero conductorProtective earthconductor (grn/yel)When connecting the machine proceed as follows:!DangerWhen connecting the machine to the mains, live machine parts can result in seriousinjuries or death!For this reason, please heed the following instructions:• Only skilled electricians may connect the machine to the mains!• You must ensure that the mains supply line is dead when connecting the machine!• The mains supply line must only be led into the switch cabinet through the borehole on the floor of the switch cabinet designed for that purpose!• In general when laying the mains supply line, make certain it is properly fastened.Under no circumstances may it come in contact with movable machine parts!• To continue, see the following page!53

Transport and installation• Turn off the power to the mains supply line!• Lay the mains supply line and guide it into the switch cabinet through the borehole designed for that purpose on the floor of the switch cabinet.ImportantIf the mains supply line is fed into the machine from above, it should be laid at thecorresponding position [A] (see graphic 1).• Make the mains power connection in the switch cabinet according to graphic 2.Make sure that the connection of the mains supply line is done on the shortestway from the bore to the connection point.Connect the designated lines according to the circuit diagram to terminalsL1, L2, L3, N, and PE.Pneumatic connectionWhen connecting your in-house supply to the machine, make sure that the connectionis effected by means of a flexible pneumatic hose (internal diameter 11 mm andexternal diameter 16 mm) and a quick-acting gate coupling (nominal width 7).54

Transport and installationC 30Arrangement of theprecision padsSize 2470-791501441810front: 1450back: 1500C 40Size 2470-791501441970front: 1650back: 1700When positioning the enclosed precision pads observe the graphics given above.Make sure that the precision pads are located in the middle position (74 mm) andthe adjusting screw of the two front pads points towards the front side of the machineand the adjusting screw of the rear ones towards the rear of the machine.55

Transport and installationTransport by fork lifttruckSituation: Right-side transportation (preferably)Situation: Left-side transportation56

Transport and installationTransport informationTraverseTransport informationmin. 956 (C 30) 1146 (C 40)max. 1556 (C 30) 1746 (C 40)Fork of the fork lift truck57

Transport and installationProcedure:!DangerWhen transporting the machine by fork lift truck, suspended loads or wrong handlingcan result in serious injuries or death.For this reason, please heed the following instructions:• The transport of the machine by fork lift truck may only be performed by sufficientlyqualified personnel or by a forwarding company authorized by theHermle AG.• Only use means of transport (forklift trucks, lifting trucks etc.) having sufficientlifting power, i.e. more than the indicated transport weight!• When transporting the machine with the fork lift truck, observe the required:–––Minimum lifting capacity of the forklift truck of 12000 kgFork length for C 30:min. 1500 mm (transport from the right side)min. 2000 mm (transport from the left side)Fork length for C 40:min. 1600 mm (transport from the right side)min. 2100 mm (transport from the left side)• If no fork lift truck meeting the requirements is available on-site, contact a forwardingcompany qualified to transport the machine by means of an appropriatefork lift truck!Other forms of transport except transport by crane or by heavy load rollers arenot allowed!• The machine may be transported by fork lift truck only complete with pallet!• When driving the forks into the transport pallet, it is essential to ensure that theforks are inserted through the openings provided for this purpose in the transportpallet as far as the opposite traverse (see graphic). Otherwise, there isa risk of toppling!• Lift and put down the machine only vertically, steadily, and without jerky movements!• During machine transport, keep unauthorized persons out of the danger area!• People must never be allowed to stand under heavy loads!• Make certain the transport routes are safe and take appropriate safety measures,if necessary!58

Transport and installation• Drive the forks of the fork lift truck from the right side (exceptionally also fromthe left) into the recesses of the transport pallet provided for this purpose and liftthe whole machine carefully. When driving in ensure that the forks reach as far asthe opposite traverse (see graphic). Otherwise, there is a risk of toppling!• Transport the machine only to its installation site.If it is not possible to place the machine directly on the corresponding installationsite using the fork lift truck, the machine must be transported further with acrane or heavy load rollers, depending on the situation. Proceed in accordancewith the instructions given in the chapter "Transport by crane" and/or the chapter"Transport by heavy load rollers".• Please unpack the machine and its components carefully, check whether thedelivered goods are complete and inspect them for possible damage duringtransport. Should any damage be detected, please notify the Hermle AG ServiceDepartment at once.• Detach and/or remove all enclosed machine parts (control panel, etc.) from the transportpallet and screw in completely the levelling feet of the electrical cabinet.• Unscrew the bolted connections holding the machine to the transport pallet(wrench size 24).• Lift the machine vertically by crane as far as necessary and remove the pallet.When doing this, make sure that the operating panel be not damaged. Proceedin accordance with the instructions given in the chapter "Transport by crane".• Then position the precision pads under the floor contact areas of the machine.Proceed in accordance with the instructions given in the chapter "Arrangementof the precision pads".• To continue, see the following page.59

Transport and installation• Lower the machine carefully and almost entirely onto the first precision pad(it should still be possible to shift the precision pad under the floor contact area).• Following this, turn the threaded rod by hand, from the top, through the hole inthe floor contact area into the threaded bore of the precision pad.Make sure that you turn the threaded rods on the front of the machine into theouter threaded bores of the precision pads and on the rear of the machine intothe inner threaded bores of the precision pads!• If it is necessary to compensate for deviations as set out in the "Dimension sheetfor floor evenness at the machine location", slide the required support plate (s)between the precision pad and the machine leg prior to lowering the machine.• Finally, lower the machine completely onto the precision pad.• Repeat this procedure for every further precision pad until the machine then standsentirely on the precision pads.60

Transport and installationImportantUnder no circumstances should the precision pads be screwed down completelyonto the floor contact areas of the machine!If the precision pads are screwed completely down to the floor contact areas, thiscan lead to damage to the precision pads when the machine is aligned.• During the commissioning of the machine, the Hermle Service Department takescare of screwing down the precision pads completely onto the floor contact areasand performing an exact alignment of the machine.• Remove the lifting device (four lifting eyes and cross-beam) in the inside of themachine (if necessary, keep them for a possible later transport – otherwise sendthem back to Hermle AG).• Place a level on the machine table afterward to make a horizontal check. Byturning the adjusting screw on the side of the precision pads, you can obtain ahorizontal alignment of the machine.61

Transport and installationTransport by craneC 30 – Transport with traverse beam1324Lifting eyes(Lifting device)1344NoteTo reach the correct ropedimension or to align themachine horizontally, theropes can also be extendedby means of shackles.Always make certain themachine is suspended horizontallyon the crane!1500 – 1700515 103962

Transport and installationC 30 – Transport with H-frame522802532 812Lifting eyes(Lifting device)NoteTo reach the correct ropedimension or to align themachine horizontally, theropes can also be extendedby means of shackles.Always make certain themachine is suspended horizontallyon the crane!1500 – 1700515 103963

Transport and installationC 40 – Transport with traverse beam1544Lifting eyes(Lifting device)1544NoteTo reach the correct ropedimension or to align themachine horizontally, theropes can also be extendedby means of shackles.Always make certain themachine is suspended horizontallyon the crane!1500 – 1700726 98764

Transport and installationC 40 – Transport with H-frame677867677 867Lifting eyes(Lifting device)NoteTo reach the correct ropedimension or to align themachine horizontally, theropes can also be extendedby means of shackles.Always make certain themachine is suspended horizontallyon the crane!1500 – 1700726 98765

Transport and installationProcedure:!DangerWhen transporting the machine by crane, suspended loads or wrong handling canresult in serious injuries or death.For this reason, please heed the following instructions:• The transport of the machine by crane may only be performed by sufficiently qualifiedpersonnel or by a forwarding company authorized by the Hermle AG.• Only use means of transport and lifting equipment (cranes, lifting frames,ropes, etc.) with sufficient lifting power, i.e. more than the indicated transportweight!• To transport the machine by crane, use only a suitable traverse beam orH-frame.• Ropes or chains of equal length must be used to suspend the machine fromthe crane beam (1500 mm – 1700 mm)!• When transporting the machine with the crane, observe the required:–––Minimum lifting force of the crane of 12000 kgMinimum load capacity of the crane cross-beam: 12000 kgindividual load capacity for each rope / chain of at least 5000 kg• If no crane meeting the requirements is available on-site, contact a forwardingcompany qualified to transport the machine by means of an appropriatecrane!Other forms of transport are not allowed except transporting by fork lift truck orby heavy load rollers!• Affix your lifting tackles only to the HERMLE lifting devices provided for thispurpose (see graphic)!• Make sure that the weight is evenly distributed to all lifting tackles!• Lift and put down the machine only suspended horizontally, steadily, and withoutjerky movements!• During machine transport, keep unauthorized persons out of the danger area!• People must never be allowed to stand under heavy loads!• Make certain the transport routes are safe and take appropriate safety measures,if necessary!66

Transport and installation• Hang the transport ropes of the crane cross-beam into the lifting eyes on thebody of the machine.• Tighten the transport ropes carefully, making sure that the four transport ropesare free and will not damage any part of the machine upon lifting.• Now lift the machine vertically by crane and transport the machine to the intendedinstallation site.If it is not possible to place the machine directly on the corresponding installationsite using the crane, the machine must be transported further by means of thefork lift truck or the heavy load rollers, depending on the situation. Proceed inaccordance with the instructions given in the chapter "Transport by fork lift truck"and/or the chapter "Transport by heavy load rollers".• Please unpack the machine and its components carefully, check whether thedelivered goods are complete and inspect them for possible damage duringtransport. Should any damage be detected, please notify the Hermle AG ServiceDepartment at once.• Detach and/or remove all enclosed machine parts (control panel, etc.) from the transportpallet and screw in completely the levelling feet of the electrical cabinet.• Unscrew the bolted connections holding the machine to the transport pallet(wrench size 24).• Lift the machine vertically by crane as far as necessary and remove the pallet.When doing this, make sure that the operating panel be not damaged.• Then position the precision pads under the floor contact areas of the machine.Proceed in accordance with the instructions given in the chapter "Arrangementof the precision pads".• To continue, see the following page.67

Transport and installation• Lower the machine carefully and almost entirely onto the first precision pad(it should still be possible to shift the precision pad under the floor contact area).• Following this, turn the threaded rod by hand, from the top, through the hole inthe floor contact area into the threaded bore of the precision pad.Make sure that you turn the threaded rods on the front of the machine into theouter threaded bores of the precision pads and on the rear of the machine intothe inner threaded bores of the precision pads!• If it is necessary to compensate for deviations as set out in the "Dimension sheetfor floor evenness at the machine location", slide the required support plate (s)between the precision pad and the machine leg prior to lowering the machine.• Finally, lower the machine completely onto the precision pad.• Repeat this procedure for every further precision pad until the machine then standsentirely on the precision pads.ImportantUnder no circumstances should the precision pads be screwed down completelyonto the floor contact areas of the machine!If the precision pads are screwed completely down to the floor contact areas, thiscan lead to damage to the precision pads when the machine is aligned.• During the commissioning of the machine, the Hermle Service Department takescare of screwing down the precision pads completely onto the floor contact areasand performing an exact alignment of the machine.• Remove the lifting device (four lifting eyes and cross-beam) in the inside of themachine (if necessary, keep them for a possible later transport – otherwise sendthem back to Hermle AG).• Place a level on the machine table afterward to make a horizontal check. By turningthe adjusting screw on the side of the precision pads, you can obtain a horizontalalignment of the machine.68

Transport and installationRequired auxiliary equipment3 heavy load rollers(2 rigid, 1 steerable)Minimum load capacity6000 kgTransport by heavyload rollers4 rubber supports(position themaccordingly)Figure 11 hardwood support(appropriate size)1 lifting pad(preferably!)Minimum load capacity8000 kgFigure 2Hydraulic jack,if necessaryMinimum load capacity8000 kgFigure 369

Transport and installationMachine from thefloor onto the heavyload rollersOrder of the lifting points for the lifting pad/hydraulic jackHeavy load rollers, rigidSwitch cabinet1.Machine base unit2.Steel plateHardwood supports3.Heavy load roller, steerableGraphic 11.2.3.70

Transport and installationOrder of the lifting points for the lifting pad/hydraulic jackHeavy load rollers, rigidMachine from theheavy load rollersonto the precisionpadsSwitch cabinet3.Machine base unit2.Steel plateHardwood supports1.Heavy load roller, steerableGraphic 21.2.3.71

Transport and installationRepresentation of the same lifting points but with hydraulic jackAttachment pointfront leftAttachment pointlaterally rightAttachment pointrear left (inside)72

Transport and installationProcedure:!WarningWhen transporting the machine by heavy load rollers, wrong handling can resultin serious injuries or death.For this reason, please heed the following instructions:• Before you put the machine on the heavy load rollers, move it by fork lift truckand/or crane as close as possible to its installation site. It is imperative to observethe safety instructions and procedures in the chapters "Transport by forklift truck" and/or "Transport by crane"!• The transport of the machine by heavy load rollers may only be performed bysufficiently qualified personnel or by a forwarding company authorized by theHermle AG.• Only use means of transport (heavy load rollers, hydraulic jack etc.) havingsufficient lifting power, i.e. more than the indicated transport weight!• When transporting the machine with heavy load rollers, observe the required:––Individual load capacity for each heavy load roller of 6000 kgMinimum lifting power of the hydraulic jack or lifting pad of 8000 kg• If no heavy load rollers meeting the requirements are available on-site, contacta forwarding company qualified to transport the machine by means of appropriateheavy load rollers.Other forms of transport are not allowed except transporting by forklift truck orby crane!• During machine transport, keep unauthorized persons out of the danger area!• People must never be allowed to stand under heavy loads!• Make certain the transport routes are safe and take appropriate and necessarysafety measures!• When the machine is not moved on the heavy load roller mechanism, the heavyload rollers must be secured to prevent them from rolling away unintentionally!73

Transport and installation!CautionWhen transporting the machine by heavy load rollers, wrong handling can resultin injuries. This may also result in material damage to the machine and anythingnearby.For this reason, please heed the following instructions:• The lifting pad and/or the hydraulic jack may only be applied (see graphic 1and graphic 2):–––––to the described pointsin the described order ( 1. 2. 3. )with a corresponding big intermediate layer (e.g. hardwood board)on clean contact surfacesand in the way shown• Transport the machine by fork lift truck and/or crane as close to its installation siteas possible. It is imperative to observe the safety instructions and procedures inthe chapters "Transport by fork lift truck" and/or "Transport by crane"!• Please unpack the machine and its components carefully, check whether thedelivered goods are complete and inspect them for possible damage duringtransport. Should any damage be detected, please notify the Hermle AG ServiceDepartment at once.• Detach and/or remove all enclosed machine parts (control panel, etc.) from the transportpallet and screw in completely the levelling feet of the electrical cabinet.• Unscrew the bolted connections holding the machine to the transport pallet(wrench size 24).• The subsequent lifting of the machine from the transport pallet and the setting itdown on the heavy load rollers must be done by crane.To continue, see the following page.74

Transport and installation• Lift the machine vertically by crane as far as necessary and remove the pallet.When doing this, make sure that the operating panel be not damaged. Proceedin accordance with the instructions given in the chapter "Transport by crane".• Lower the machine vertically, evenly and without jerky movements onto the correspondinglypositioned heavy load rollers (see illustration 1). Make sure all heavyload rollers point in the direction of travel.If the machine must be put on the heavy load rollers from the floor, proceed stepwiseas described in graphic 1. When placing the machine on the front heavy loadrollers, secure the rear heavy load rollers with rubber pads against unintentionalrolling away (see figure 1)!• Now you can push the machine on the heavy load rollers to its installation site.Make sure that the machine does not slip or tilt during the transport!• When the machine stands on its installation site, secure both rear heavy load rollerswith suitable rubber pads (as shown in figure 1) and put a lifting pad to position1. (as shown in graphic 2).• Pump the machine upward, until you can remove both of the wooden supports.Position thereupon two precision pads under the floor contact areas of the machine(at the front right and left). Proceed in accordance with the instructions given inthe chapter "Arrangement of the precision pads".• Lower the machine carefully and almost entirely onto the precision pads (it shouldstill be possible to shift the precision pads under the floor contact area).• Following this, turn the threaded rods by hand, from the top, through the hole inthe floor contact areas into the outer threaded bore of the precision pads.• If it is necessary to compensate for deviations as set out in the "Dimension sheetfor floor evenness at the machine location", slide the required support plate (s)between the precision pad and the machine leg prior to lowering the machine.• Then lower the machine down completely onto the two front precision pads.• Place the lifting pad in position 2. (as per graphic 2).75

Transport and installation• Pump the machine up, until you can remove the right rear heavy load roller.Then position a precision pad under the floor contact area of the machine(at the rear right). Proceed in accordance with the instructions given in the chapter"Arrangement of the precision pads".• Lower the machine carefully and almost entirely onto the precision pad (it shouldstill be possible to shift the precision pad under the floor contact area).• Then turn the threaded rods by hand, from the top, through the hole in the floorcontact areas into the inner threaded bore of the precision pad.• If it is necessary to compensate for deviations as set out in the "Dimension sheetfor floor evenness at the machine location", slide the required support plate (s)between the precision pad and the machine leg prior to lowering the machine.• Finally, lower the machine completely onto the precision pad.• Thereupon apply the lifting pad to position 3. (as per Graphics 2).• Pump the machine upward, until you can remove the left rear heavy load roller.Then position a precision pad under the floor contact area of the machine(at the rear right). Proceed in accordance with the instructions given in the chapter"Arrangement of the precision pads".• Lower the machine carefully and almost entirely onto the precision pad (it shouldstill be possible to shift the precision pad under the floor contact area).• Then turn the threaded rods by hand, from the top, through the hole in the floorcontact areas into the inner threaded bore of the precision pad.• If it is necessary to compensate for deviations as set out in the "Dimension sheetfor floor evenness at the machine location", slide the required support plate (s)between the precision pad and the machine leg prior to lowering the machine.• Finally, lower the machine completely onto the precision pad.76

Transport and installationImportantUnder no circumstances should the precision pads be screwed down completelyonto the floor contact areas of the machine!If the precision pads are screwed completely down to the floor contact areas, thiscan lead to damage to the precision pads when the machine is aligned.• During the commissioning of the machine, the Hermle Service Department takescare of screwing down the precision pads completely onto the floor contact areasand performing an exact alignment of the machine.• Remove the lifting device (four lifting eyes and cross-beam) in the inside of themachine (if necessary, keep them for a possible later transport – otherwise sendthem back to Hermle AG).• Place a level on the machine table afterward to make a horizontal check. Byturning the adjusting screw on the side of the precision pads, you can obtain ahorizontal alignment of the machine.77

Transport and installationTransport of the additionalmagazinesZM 43 and ZM 871 41322Additional magazine 43Additional magazine 87Transport weightAdditional magazine ZM 43Additional magazine ZM 87Enclosure for ZM 43Enclosure for ZM 87approx. 740 kgapprox. 830 kgapprox. 400 kgapprox. 400 kgTransport dimensionsAdditional magazine ZM 43 (L x W x H)Additional magazine ZM 87 (L x W x H)Enclosure for ZM 43 (L x W x H)Enclosure for ZM 87 (L x W x H)2000 x 2000 x 2100 mm2000 x 2000 x 3050 mm2400 x 1500 x 2000 mm2400 x 1500 x 2000 mm78

Transport and installationImportantTransport - centre ofgravityWhen transporting the additional magazine, make certain to note where the centre ofgravity is and to arrange the transporting equipment and lifting tackles accordingly!The transport centre of gravity is identified on the additional magazine / shippingpackage by the following symbol.Front view (for ZM 43 and ZM 87)1011707891278377Side view (for ZM 43 and ZM 87)118170789127827679

Transport and installationTransport information• Set the additional magazine with the transport device down directly next to themachine.• Hermle Service will connect the additional magazine to the machine and align itprecisely during the machine start-up procedure.• Please return the transport aids (transport device etc.) after the machine has beencommissioned.ImportantLeave the set-up templates included with delivery with the machine in case of possiblelater transport.80

Transport and installationProcedure:Transport by forklifttruck!DangerWhen transporting the additional magazines by forklift truck, suspended loads orwrong handling can result in serious injuries or death.For this reason, please heed the following instructions:• The transport of the additional magazine by fork lift truck may only be performedby sufficiently qualified personnel or by a forwarding company authorized bythe Hermle AG.• Only use means of transport (forklift trucks, lifting trucks etc.) having sufficientlifting power, i.e. more than the indicated transport weight!• When transporting the additional magazine with the fork lift truck, observe therequired:––Minimum lifting capacity of the forklift truck of 3000 kgFork length of 1500 mm• If no forklift truck meeting the requirements is available on-site, contact a forwardingcompany qualified to transport the additional magazine by means ofan appropriate forklift truck!Other forms of transport are not allowed, except transporting by crane!• The additional magazine may be transported by forklift truck only completewith pallet!• The transport bar [3] of the additional magazine may only be used to lift theadditional magazine from the pallet!• When driving in the forks into the transport pallet, it is essential to ensure thatthe forks are inserted far enough into the transport pallet. Otherwise, there isa risk of toppling!• Lift and put down additional magazine only vertically, evenly and without jerkymovements!• During transport of the additional magazine, keep unauthorized persons out ofthe danger area!• People must never be allowed to stand under heavy loads!• Make certain the transport routes are safe and take appropriate safety measures,if necessary!81

Transport and installation• Drive the forks of the forklift truck into the transport pallet and carefully lift theentire additional magazine.• Transport the additional magazine to the intended installation site.If the additional magazine cannot be positioned directly at the desired installationsite using the forklift truck, the transport of the additional magazine must be continuedby crane. Proceed in accordance with the instructions given in the chapter"Transport by crane".• Please unpack the additional magazine and its components carefully, checkwhether the delivered goods are complete and inspect them for possible damageduring transport. Should any damage be detected, please notify the Hermle AGService Department at once.• Insert the transport bar included on the pallet [3] into the openings that beforewere closed with dummy plugs.• Attach the two reusable pins [4] to the transport bar [3] as right and left lateralarresters.• Unscrew the threaded bars [2] of the additional magazine from the transportpallet.• Drive the forks of the forklift truck under the transport bar [3].• Lift the additional magazine vertically and carefully by only the amount neededand pull the pallet away.• Carefully lower the additional magazine to 4 wooden blocks about 30 cm inheight.• Screw in the adjusting legs included in the delivery in place of the threadedbars [2].• Lift the additional magazine vertically and carefully by only the amount neededonce again and pull the wooden blocks away.• Carefully lower the additional magazine onto the adjusting legs.• Hermle Service will connect the additional magazine to the machine and align itprecisely during the machine start-up procedure.82

Transport and installationProcedure:Transport by crane!DangerWhen transporting the additional magazines by crane, suspended loads or wronghandling can result in serious injuries or death.For this reason, please heed the following instructions:• The transport of the additional magazine by crane may only be performed bysufficiently qualified personnel or by a forwarding company authorized by theHermle AG.• Only use means of transport and lifting equipment (cranes, lifting frames, ropes, etc.)with sufficient lifting power, i.e. more than the indicated transport weight!• To transport the additional magazine by crane, use exclusively a crane crossbeamof suitable design.• When transporting the additional magazine with the crane, observe the required:–––Minimum lifting force of the crane of 3000 kgThe wire cable or chain set must have a minimum length of 60 cmThe wire rope or chain set must have a minimum lifting capacityof 3000 kg• If no crane meeting the requirements is available on-site, contact a forwardingcompany qualified to transport the additional magazine by means of an appropriatecrane!Other forms of transport are not allowed except transporting by forklift truck!• Attach your lifting tackle only to the lifting eye provided for this purpose(lifting device) [1]!• Make sure that the weight is evenly distributed to all lifting tackles!• Lift and put down the additional magazine only suspended horizontally, steadily,and without jerky movements!• During transport of the additional magazine, keep unauthorized persons out ofthe danger area!• People must never be allowed to stand under heavy loads!• Make certain the transport routes are safe and take appropriate safety measures,if necessary!83

Transport and installation• Hang a strand of the wire rope or chain set into each of the lifting eyes(lifting device) [1] on the body of the additional magazine (see illustration).• Tighten the transport ropes carefully, making sure that the transport ropes are freeand will not damage any part of the additional magazine upon lifting.• Transport the additional magazine to the intended installation site.If the additional magazine cannot be positioned directly at the desired installationsite using the forklift truck, transport of the additional magazine must be continuedby crane. Proceed in accordance with the instructions given in the chapter"Transport by forklift truck".• Please unpack the additional magazine and its components carefully, checkwhether the delivered goods are complete and inspect them for possible damageduring transport. Should any damage be detected, please notify the HERMLE AGService Department at once.• Unscrew the threaded bars [2] of the additional magazine from the transportpallet.• Lift the additional magazine vertically and carefully by only the amount neededand pull the pallet away.• Carefully lower the additional magazine to 4 wooden blocks about 30 cm inheight.• Screw in the adjusting legs included in the delivery in place of the threadedbars [2].• Lift the additional magazine vertically and carefully by only the amount neededonce again and pull the wooden blocks away.• Carefully lower the additional magazine to the adjusting legs.• Hermle Service will connect the additional magazine to the machine and align itprecisely during the machine start-up procedure.84

Transport and installationTransport weightAdditional magazine ZM 157approx. 6000 kgTransport of the additionalmagazineZM 157Transport dimensionsAdditional magazine ZM 15723302350170345085

Transport and installationTransport - centre ofgravityImportantWhen transporting the additional magazine, make certain to note where the centre ofgravity is and to arrange the transporting equipment and lifting tackles accordingly!The transport centre of gravity is identified on the additional magazine / shippingpackage by the following symbol.front view1017260170Side view101745086

Transport and installationTransport information• Set the additional magazine with the transport device and the heavy load rollersdown directly next to the machine.• Hermle Service will bolt the precision pads to the floor contact areas, connectthe additional magazine to the machine and align it precisely during the machinestart-up procedure.• Please return the transport aids (transport device, heavy load rollers, etc.) afterthe machine has been commissioned.ImportantLeave the set-up templates included with delivery with the machine in case of possiblelater transport.87

Transport and installation12200200117539-5111751095 1095Arrangement of the precision padsNoteHermle Service will attach and adjust the precision pads during the initial machinestart-up procedure.When positioning the precision pads, use the graphics listed above for orientation.Make sure that the precision pads are positioned in such a way that the adjustingscrews for all precision pads are pointing outwards.During transport the precision pads of the additional magazine are screwed to thepallet. For the additional magazine to be lifted from the transport pallet, the threeprecision pads must be unscrewed.The precision pads must be screwed to the floor contact areas for the additionalmagazine using the threaded rod [1]. First, three spacer plates [2] must be placedbetween each precision pad and floor contact area.88

Transport and installationTransport by forklifttruck and heavyload rollersGraphic 18001400Fork of the fork lift truckAGraphic 2B125089

Transport and installationGraphic 3CDGraphic 4EE8001400Fork of the fork lift truck90

Transport and installationFGFFGGraphic 5127691

Transport and installationProcedure:!DangerWhen transporting the additional magazine by forklift truck and heavy load rollers,suspended loads or wrong handling can result in serious injuries that maybecome fatal.For this reason, please heed the following instructions:• Transport of the additional magazine by forklift truck and heavy load rollersmay only be performed by sufficiently qualified personnel or by a forwardingcompany authorized by Hermle AG!• Only use means of transport (fork lift trucks, heavy load rollers) with sufficientlifting power, i.e. more than the indicated transport weight!• When transporting the additional magazine by fork lift truck and heavy loadrollers, observe the following requirements:––––Minimum lifting capacity of the forklift truck of 6000 kgFork length of the forklift truck of min. 1800 mmDrive-in depth of the forks of the forklift truck between 1800 mm and2100 mm.Otherwise, there is a risk of tipping or damaging the enclosurearound the additional magazine!Minimum load capacity of each heavy load roller of 3000 kg• If no forklift truck meeting the requirements is available on-site, contact a forwardingcompany qualified to transport the additional magazine by means ofan appropriate forklift truck!Other forms of transport except transport by crane and heavy load rollers arenot allowed!• The additional magazine may only be transported from the left side (with andwithout transport pallet) (see illustration 1)!• When transporting the additional magazine with no transport pallet be awareof the conduit on the underside of the additional magazine. Place rubber matson the forks of the forklift to prevent any damage.• Lift and put down additional magazine only vertically, evenly and without jerkymovements!• During transport of the additional magazine, keep unauthorized persons out ofthe danger area!• People must never be allowed to stand under heavy loads!• Make certain the transport routes are safe and take appropriate safety measures,if necessary!• If the additional magazine is not being moved on the heavy load rollers, the heavyload rollers must be secured to prevent it from rolling away unintentionally.92

Transport and installation• Approach with the forklift truck from the left side, insert the forks into the transportpallet and carefully lift the complete additional magazine (illustration 1).• Transport the additional magazine to the intended installation site.If the additional magazine cannot be positioned directly at the desired installationsite using the forklift truck, transport of the additional magazine must be continuedby crane (refer to the section "Transport by crane") or the heavy load rollers(as described in the following).• Please unpack the additional magazine and its components carefully, checkwhether the delivered goods are complete and inspect them for possible damageduring transport. Should any damage be detected, please notify the Hermle AGService Department at once.• Remove all accompanying parts from the transport pallet.• Loosen all three bolted connections holding the precision pads to the transportpallet.• Fasten the transport bracket provided [A] to the additional magazine and screwthe appropriate heavy load rollers [B] with the threaded rod [1] securely to thetransport bracket [A].Make sure that the threaded rod [1] is screwed into the heavy load rollers [B] upto the stop and the lock nut [2] is loose.The threaded rod [1] must be screwed far enough into the transport bracket[A] so that it still protrudes 50 mm out of the top of the transport bracket [A](graphic 2)!• Secure each threaded rod [1] by tightening the lock nut [2] down against the heavyload rollers [B] (illustration 2).• Screw in the adjusting feet [C] of the enclosure panels completely and removethe drawbar [D] of the attached heavy load roller vehicle (illustration 3).• Approach with the forklift truck from the left side and insert the forks into the openings[E] provided in the additional magazine (illustration 4).• Lift the additional magazine vertically and carefully by only the amount neededand pull the pallet away.93

Transport and installation• Position the two other heavy load rollers [G] under the two other previously attachedtransport brackets [F] (illustration 5).• Screw the two heavy load rollers [G] each together with a threaded rod [1] on thetransport bracket [F].Make sure that the threaded rod [1] is screwed into the heavy load rollers [G] upto the stop and the lock nut [2] is loose.The threaded rod [1] must be screwed far enough into the transport bracket [F]so that it still protrudes 76 mm out of the top of the transport bracket [F](illustration 5)!• Secure each threaded rod [1] by tightening the lock nut [2] down against the heavyload rollers [G] (illustration 5).• Lower the additional magazine carefully and evenly onto the heavy load rollersand make sure that the additional magazine is resting on the heavy load rollersand not on other parts of the machine. Otherwise the threaded rods [1] must bescrewed correspondingly further into the transport brackets.• Re-attach the previously removed drawbar to the heavy load roller mechanism.• Now transport the additional magazine to its installation location (close to themachine) on the heavy load rollers.Leave the heavy load rollers attached to the additional magazine.• Secure the heavy load rollers to prevent them from rolling away unintentionally!• Hermle Service will bolt the precision pads to the floor contact areas, connectthe additional magazine to the machine and align it precisely during the machinestart-up procedure.94

Transport and installationTransport with H-frameTransport by craneand heavy loadrollers999867289157Lifting eyes(Lifting device)NoteTo reach the correct ropedimension or to align themachine horizontally, theropes can also be extendedby means of shackles.Always make certain themachine is suspended horizontallyon the crane!min. 1100 mm456337min. 1440 mm95

Transport and installationGraphic 1Graphic 2AB125096

Transport and installationGraphic 3CDFFGraphic 4GG127697

Transport and installationProcedure:!DangerWhen transporting the additional magazine by crane and heavy load rollers, suspendedloads or wrong handling can result in serious injuries that may becomefatal.For this reason, please heed the following instructions:• Transport of the additional magazine by crane and heavy load rollers may onlybe performed by sufficiently qualified personnel or by a forwarding companyauthorized by Hermle AG!• Only use means of transport and lifting tackle (cranes, cross-beams, ropes,heavy load rollers, etc.) having sufficient lifting power, i.e. more than the indicatedtransport weight!• To transport the additional magazine by crane, use only a suitable H-frame.• When transporting the additional magazine by crane and heavy load rollers,observe the required:–––––Minimum lifting force of the crane of 6000 kgMinimum load capacity of the crane cross-beam: 6000 kgIndividual load capacity of each heavy load roller: at least 5000 kgLength of the lifting ropes, front min. 1100 mm / rear min. 1440 mmMinimum load capacity of each heavy load roller: 3000 kg• If no crane meeting the requirements is available on-site, contact a forwardingcompany qualified to transport the additional magazine by means of an appropriatecrane!Other forms of transport are not allowed except transporting by forklift truckand heavy load rollers!• Affix your lifting tackle only to the lifting eyes provided for this purpose!• Make sure that the weight is evenly distributed to all lifting tackles!• Lift and put down the additional magazine only suspended horizontally, steadily,and without jerky movements!• During transport of the additional magazine, keep unauthorized persons out ofthe danger area!• People must never be allowed to stand under heavy loads!• Make certain the transport routes are safe and take appropriate safety measures,if necessary!• If the additional magazine is not being moved on the heavy load rollers, the heavyload rollers must be secured to prevent it from rolling away unintentionally.98

Transport and installation• Insert one of the transport ropes from the crane beam into each of the lifting eyeson the body of the additional magazine (illustration 1).• Tighten the transport ropes carefully, making sure that the transport ropes are freeand will not damage any part of the additional magazine upon lifting.• Transport the additional magazine to the intended installation site.If the additional magazine cannot be positioned directly at the desired installationsite using the crane, transport of the additional magazine must be continued byforklift truck (refer to the section "Transport by forklift truck") or the heavy loadrollers (as described in the following).• Please unpack the additional magazine and its components carefully, checkwhether the delivered goods are complete and inspect them for possible damageduring transport. Should any damage be detected, please notify the Hermle AGService Department at once.• Remove all accompanying parts from the transport pallet.• Loosen all three bolted connections holding the precision pads to the transportpallet.• Fasten the transport bracket provided [A] to the additional magazine and screwthe appropriate heavy load roller mechanism [B] with the threaded rod [1] securelyto the transport bracket [A].Make sure that the threaded rod [1] is screwed into the heavy load roller mechanism[B] up to the stop and the lock nut [2] is loose.The threaded rod [1] must be screwed far enough into the transport bracket [A]so that it still protrudes 50 mm out of the top of the transport bracket [A](graphic 2)!• Secure each threaded rod [1] by tightening the lock nut [2] down against theheavy load roller mechanism [B] (illustration 2).• Screw in the adjusting feet [C] of the enclosure panels completely and removethe drawbar [D] of the attached heavy load roller vehicle (illustration 3).• Lift the additional magazine vertically and carefully by only the amount neededand pull the pallet away.99

Transport and installation• Position the two other heavy load roller mechanisms [G] under the two otherpreviously attached transport brackets [F] (illustration 4).• Screw the two heavy load roller mechanisms [G] each together with a threadedrod [1] on the transport bracket [F].Make sure that the threaded rod [1] is screwed into the heavy load roller mechanism[G] up to the stop and the lock nut [2] is loose.The threaded rod [1] must be screwed far enough into the transport bracket [F]so that it still protrudes 76 mm out of the top of the transport bracket [F](illustration 4)!• Secure each threaded rod [1] by tightening the lock nut [2] down against the heavyload roller mechanism [G] (illustration 4).• Lower the additional magazine carefully and evenly onto the heavy load rollersand make sure that the additional magazine is resting on the heavy load rollersand not on other parts of the machine. Otherwise the threaded rods [1] must bescrewed correspondingly further into the transport brackets.• Re-attach the previously removed drawbar to the heavy load roller mechanism.• Now transport the additional magazine to its installation location (close to themachine) on the heavy load rollers.Leave the heavy load rollers attached to the additional magazine.• Secure the heavy load rollers to prevent them from rolling away unintentionally!• Hermle Service will bolt the precision pads to the floor contact areas, connectthe additional magazine to the machine and align it precisely during the machinestart-up procedure.100

ChapterMachine dimensions and machineweight101

Machine dimensions and machine weightC 30Machine dimension660 855600Ejection height ofswarf conveyor1100 mmR 10201a5385010003403480294011510In-houseconnectionElectrical6507853095601000In-house connectionPneumatic system10In-house connection150144Electrical14502110231500Pull-outdimensions:Swarfconveyor2100 mmSwarfdrawer1800 mm1000370685111810380120 446045R 915R 1650638105030R 10200102

Machine dimensions and machine weight041003670880 331024702100370307020001260 9105a115b4404 5 6176023103100 9701 Internal Coolant Supply1aRecooling unit2 Swarf cart3 Swarf conveyor4 Additional magazine ZM 435 Additional magazine ZM 875a5bTool handlingDriving motor6 Additional magazine ZM 1577 Cooling unit FLKS 4 or KGL 68 Fluid cabinet9 Oil mist extraction10 Standard machine11 Swivel drive - A-axis103

Machine dimensions and machine weightC 30Machine weightTotal weight of the standard machine C 30 Weight of the additional magazine ZM 157approx. 9400 kgapprox. 5800 kgC 30Static load of standardmachineNoteThe following load values of the individual precision pads (labelled A, B, C and D)are based on static measurements at different positions of the milling spindle inthe working area (labelled from 1 to 5). These load values depend on the adjustmentof the precision pads and how the machine is equipped!The measurements were carried out on a specific machine model without tools, workpieces, clamping devices, coolant pan, swarf drawer or options!Switch cabinetDBasic body of the machineC5Working area14A2 3BMilling spindlepositionPrecision pad / loadA ( kg ) B ( kg ) C (kg) D (kg)1 1401 1827 1715 31002 1600 1848 1516 30693 1411 2040 1663 29184 1209 1786 1924 31165 1385 1610 1762 3276104

Machine dimensions and machine weightNoteC 30Dynamic load ofstandard machineThe following load values of the individual precision pads (labelled A, B, C and D)are based on dynamic measurements. These load values depend on the adjustmentof the precision pads and how the machine is equipped!The measurements were carried out on a specific machine model without tools, workpieces, clamping devices, coolant pan, swarf drawer or options!Switch cabinetDBasic body of the machineC1810Working areaAB1450Precision pad / loadA ( kg ) B ( kg ) C (kg) D (kg)min. max. min. max. min. max. min. max.567 2243 379 3037 808 3014 611 3514105

Machine dimensions and machine weightC 40Machine dimension660 855600R 10201000115101aIn-house connectionElectricalEjectionheight of swarfconveyor1100 mm1000231000Pull-outdimensions:Swarf conveyor2100 mmSwarf drawer1900 mm456R 10205380034034752940650785309560In-house connectionPneumatic system15014410In-house connectionElectrical230017001650370685111970380120 4460R 915R 1650393051600106

Machine dimensions and machine weight042203870880 351026702300370260 9105a9705b4404 5 6307013100200011176023101 Internal Coolant Supply1aRecooling unit2 Swarf cart3 Swarf conveyor4 Additional magazine ZM 435 Additional magazine ZM 875a5bTool handlingDriving motor6 Additional magazine ZM 1577 Cooling unit FLKS 4 or BL 058-138 Fluid cabinet9 Oil mist extraction10 Standard machine11 Swivel drive - A-axis107

Machine dimensions and machine weightC 40Machine weightTotal weight of the standard machine C 40Weight of the additional magazine ZM 157approx. 10700 kgapprox. 5800 kgC 40Static load of standardmachineNoteThe following load values of the individual precision pads (labelled A, B, C and D)are based on static measurements at different positions of the milling spindle in theworking area (labelled from 1 to 5). These load values depend on the adjustment ofthe precision pads and how the machine is equipped!The measurements were carried out on a specific machine model without tools, workpieces, clamping devices, coolant pan, swarf drawer or options!Switch cabinetDBasic body of the machineC5Working area14A2 3BMilling spindlepositionPrecision pad / loadA ( kg ) B ( kg ) C (kg) D (kg)1 1842 1815 2049 31472 2077 1860 1825 30983 1891 2040 2008 29094 1620 1764 2292 31805 1786 1610 2081 3393108

Machine dimensions and machine weightNoteC 40Dynamic load ofstandard machineThe following load values of the individual precision pads (labelled A, B, C and D)are based on dynamic measurements. These load values depend on the adjustmentof the precision pads and how the machine is equipped!The measurements were carried out on a specific machine model without tools, workpieces, clamping devices, coolant pan, swarf drawer or options!Switch cabinetDBasic body of the machineC1970Working areaAB1650Precision pad / loadA ( kg ) B ( kg ) C (kg) D (kg)min. max. min. max. min. max. min. max.482 2911 437 2698 849 2908 1285 4175109

110Machine dimensions and machine weight

Instructions for measuring the evenness of the surface at the machine location (C 30, C 40)Accessories:• Levelling rod with water level• Measuring stick• Support block1. Designating the machine support points at the machine locationMeasure all support points (for the machine, pallet changer, additional magazine ZM 157) at the desired installationlocation, taking into consideration the following dimension sheet, and mark them on the surface.2. Measuring surface evenness at the machine location (C 30, C 40)ab• [a] Place the levelling rod on the support block at support point "A".• [b] Align the levelling rod horizontally and measure the deviations at points B, C, and D in referenceto "A".• Enter any deviations in the following dimension sheet in Table 1.3. Measuring surface evenness at the pallet changer location (PW 800, PW 160)• [a] Place the levelling rod on the support block at support point "D".• [b] Align the levelling rod horizontally and measure the deviations at points E, F and G for PW 160 orE, F, G and H for PW 800 in reference to "D".• Enter any deviations in the following dimension sheet in Table 2.4. Measuring surface evenness at the additional magazine location (ZM 157)• [a] Place the levelling rod on the support block at support point "B".• [b] Align the levelling rod horizontally and measure the deviations at points I, J and K relative to "B".• Enter any deviations in the following dimension sheet in Table 3.

C 30Dimension sheet for surface evenness at machine locationMaschinenfabrikBerthold Hermle AGIndustriestraße 8-12D-78559 Gosheim Fax: +49 7426 95-6109Company:Street/PO Box:Postcode/City:Machine model:Date:Signature:Country:25681 Machining centre C 30JSupport point A B C D1538602 2568I32461Deviation in +/-mm from supportpoint "A"Support plates* )Number082319911356+/- 0A1132927DE309 15521217CBFK1662199138314223586Thickness (mm)2Pallet changer PW 800 (2a) / PW 160 (2b)Support point E F G HDeviation in +/-mm from supportpoint "D"Support plates* )NumberThickness (mm)3892H272aG3 Additional magazine ZM 157Support point I J K184E1401FDeviation in +/-mm from supportpoint "B"Support plates* )2bNumber345+Thickness (mm)G0-horizontal*) To be completed by Hermle Customer Service-

C 40Dimension sheet for surface evenness at machine locationMaschinenfabrikBerthold Hermle AGIndustriestraße 8-12D-78559 Gosheim Fax: +49 7426 95-6109Company:Street/PO Box:Postcode/City:Machine model:Date:Signature:Country:27151 Machining centre C 40JSupport point A B C D1685602 2715I32442Deviation in +/-mm from supportpoint "A"Support plates* )Number066521501555+/- 0A1152827DE 209 16511316CBFK1820217936314033774Thickness (mm)2Pallet changer PW 800 (2a) / PW 160 (2b)Support point E F G HDeviation in +/-mm from supportpoint "D"Support plates* )NumberThickness (mm)4050126H2aG3 Additional magazine ZM 157Support point I J K84E1501FDeviation in +/-mm from supportpoint "B"Support plates* )2bNumber445+Thickness (mm)G0-horizontal*) To be completed by Hermle Customer Service-