GRASS ZPM User manual

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Grass
ZPM
OPERATING INSTRUCTIONS

TECHNICAL DATA
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Dimensions:
Machine’s width for standard model 1600 mm
Machine’s total height @ 1800 mm
Machine’s depth @ 1000 mm
Other Specifications:
Insertion force of each side with 0.6 MPa (6 bar) @ 650 KP
Maximum total width for standard model 1000 mm
(Maximum floor width 936 mm)
Maximum front height for standard model 700 mm
Maximum back wall height for standard model 350 mm
Maximum lateral front overhang on the standard model 20 mm
Maximum lower front overhang on the standard model 100 mm
Zargen slides which can be used: 6035, 6036, 6136, 6236, 6436
Zargen lengths which can be used: 270, 350, 400, 440, 470, 510, 550
Weights:
Total weight of the basic equipment 185.00 kg
Weight of the change-over insert, length = 270 3.79 kg
Weight of the change-over insert, length = 350 3.97 kg
Weight of the change-over insert, length = 400 4.13 kg
Weight of the change-over insert, length = 440 4.31 kg
Weight of the change-over insert, length = 470 4.43 kg
Weight of the change-over insert, length = 510 4.61 kg
Weight of the change-over insert, length = 550 4.79 kg
Pneumatic Connections:
ust-, water- and oil free air pressure at least 5.5 bar
Maximum allowable setting of pressure reducer 6.5 bar
Maximum pressure in supply line 10 bar
Pneumatic air used per stroke with 6 bar 1.2 l
Pneumatic air used per stroke, suction capacity for compressor 7.2 l

TABLE OF CONTENTS
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Page
1. General 5-6
1-001 List of illustrations 5
1-002 Manufacturer information 6
1-003 Copyright information 6
1-004 Terms of the guarantee 6
2. Safety Information 7-9
2-001 Safety information 7
2-002 Usage, according to regulations 7
2-003 Other risks, according to EN 292-2 8
2-004 Safety devices 8
2-005 escription of stickers 9
2-006 anger- and safety measures 9
3. Description of Products 10-11
3-001 Usage 11
3-002 Identification of products 11
3-003 Basic equipment 11
3-004 Standard accessories 10-11
3-005 Special accessories 11
4. Description of Machine Components 12-17
4-001 Overview of numbered individual parts 12-13
4-002 escription of individual assembly parts 14-15
4-003 escription of operating elements 16
4-004 Functions of the ZPM - Producing drawers with the ZPM 16-17
5. Shipping and Installation of Machines, Service Personnel 18-19
5-001 Shipping and storage requirements, Center of gravity 18
5-002 Space and environment requirements 19
5-003 Assembly at the final installation site 19
5-004 Requirements of operating personnel 19
6. Start-Up 20-21
6-001 Pneumatic connection 20
6-002 Pneumatic diagram 20-21

TABLE OF CONTENTS
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7. Changing Over and Adjusting the ZPM 22-23
7-001 Checking the wood parts 22-23
7-002 Mounting the index stops 24-25
7-003 Setting the drawer width 24-25
7-004 Changing to another drawer width 26-27
7-005 Changing to another Zarge slide height 26-27
7-006 Changing to another Zarge slide length 26-27
7-007 Setting the back wall height stops 26-27
7-008 Setting the front height stops 28-29
7-009 Setting the front side stops 28-29
7-010 Setting the back wall thickness 30-31
7-011 Setting the bottom thickness 30-31
7-012 Setting the angles between the drawer front and drawer bottom 32-33
8. Trouble Shooting and Problem Solving 34-35
8-001 Gap between the drawer front and Zargen slide 34
8-002 Gap between the drawer bottom and bottom support with Zargen slide 34
8-003 Gap between the drawer bottom and drawer back wall 34
8-004 Gap between the Zargen slide and back wall inside the drawer 34
8-005 Gap between the Zargen slide and bottom inside the drawer 35
8-006 Correcting the angle between the drawer bottom and drawer front 35
8-007 Back wall dowel not inserted properly / Gap between the back wall and
Zargen slide 35
8-008 rawer cannot be removed easily from the Zargen press ZPM 35
9. Maintenance and Care 36
9-001 Maintenance plan 36
9-002 Care information 36
10. Miscellaneous 37-51
10-001 Guarantee certificate 37-38
10-002 isposal form 39-40
10-003 Resale form 41-42
10-004 Questionnaire 1 43-44
10-005 Questionnaire 2 45-46
10-006 List of Grass distributors 47

LIST OF ILLUSTRATIONS
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1-001 List of Illustrations
Illustration Description page
3-006 Miscellaneous standard accessories 10
4-001-01 General overview of the ZPM 12
4-002-01 Sectional view of the ZPM 14
4-002-02 Sectional view of the ZPM 14
4-004-01/.../06 Producing a drawer 16
5-001-01 Center of gravity of the Zargen slide press ZPM 18
6-002-01 Pneumatic diagram 21
7-001-01 Control dimensions for the drawer fronts for 6035 22
7-001-02 Control dimensions for the drawer fronts for
6036 / 6136 / 6236 / 6436 22
7-001-03 Control dimensions for the drawer bottoms for 6035 22
7-001-04 Control dimensions for the drawer bottoms for
6036 / 6136 / 6236 / 6436 22
7-001-05 Control dimensions for the drawer back walls for 6035 22
7-001-06 Control dimensions for the drawer back walls for
6036 / 6136 / 6236 / 6436 22
7-002-01 Mounting the index stops 24
7-003-01 Setting the drawer width 25
7-006-01 Changing to another Zargen slide length 27
7-007-01 Setting the back wall height stops 27
7-008-01 Setting the front height stops 29
7-009-01 Setting the front side stops 29
7-010-01 Setting the back wall thickness 31
7-011-01 Setting the bottom thickness 31
7-012-01 Setting the angles between the drawer front and the drawer bottom 33

1. GENERAL INFORMATION
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1-002 Manufacturer information
Grass GmbH Tel. [phone]
Grass Platz 1 Fax. [phone]
6973 Höchst Internet: www.grass.at
Austria E-Mail: [email protected]
1-003 Copyright information
The manufacturer has exclusive copyrights of these documents. Any means of copying is permitted only with
the permission of the manufacturer, unless the operating instructions are copied specifically for the purpose of
utilizing the machine.
1-004 Terms of the Guarantee
The delivered ZPM comes with a guarantee that is within the scope of the „General Terms of Guarantees in the
Association of the Machinery and Steel Construction Industry.“ Misuse of the product, repairs by
unauthorized or untrained personnel, use of unauthorized replacement parts or accessories without written ap-
proval from the manufacturer invalidate any guarantee claims.
We reserve the right to make technical modifications for whatever reason. When the machine is shipped from
the manufacturing plant, it meets the latest regulations and technical standards.
The manufacturer is under no obligation to modify machines free of charge because of changed
specifications.
To make a guarantee claim, please contact an authorized Grass representative or an authorized Grass
distributor and give them the machine model and number.
Lists of representatives and distributors can be found in Section 10-006.
Guarantee claims will only be honored if the guarantee certificate was filled out completely and sent to
the manufacturer. The guarantee form is in Section 10-001.
The guarantee and warranty include exclusively the replacement or repair of defective parts.
Not included in the guarantee are:
- shipping damages (These damage claims should be filed with the postal
service, the railway company or the shipping company.),
- natural wear and tear of parts,
- drill bits,
- damages resulting from negligence of safety regulations,
- damages resulting from inappropriate handling or misuse of the ZPM,
- damages to or from the work material,
- reimbursement of down time,
- loss of earnings or wages because of a defective ZPM,
- installation time, driving time or travel expenses.

2. SAFETY INFORMATION
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2-001 Safety Information
-It is the responsibility of the owners of the machines to make sure that only properly trained personnel
operate the machine.
- The pneumatic connection lines are to be installed correctly and are to be protected from damaging effects.
(For example, in cable channels, conduits, or something similar).
-The safety devices, which are included in the shipment, must always be utilized according to Point 2-004 and
must not be by-passed or rendered inoperable.
- uring service or maintenance work, the air pressure supply lines must be separated from the machine
(by quick coupling, for example).
- Before operating the machine again, check all safety devices thoroughly to make certain that they are
functioning properly. Replace damaged parts only with authorized parts.
- Keep the workplace and surrounding area clean. Messy and disorganized work places increase the risk
of injury.
- The work area must be completely dry. o not use the machine outside and, especially, do not leave
the machine out in the rain.
- Keep unauthorized people away from the machine.
- Only one person shall operate the machine at a time.
2-002 Recommended Usage
- The Grass Zargen press, model ZPM, is to be used expressly for the insertion of the Grass Zargen System
6000 on a wooden bottom, wooden back wall and a wooden front. Solid wood and other wood derived
materials can be used.
Other uses are not specified or allowed; thus, the manufacturer is not liable for resulting damages. The user
alone assumes all risks.
- The user must conform to the operating instructions when determining the appropriate usages.
- The machine shall only be operated, serviced and maintained by trained and authorized persons.
- The original set-up may not be modified without the express consent of Grass, Inc.

2. SAFETY INFORMATION
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2-003 Risks according to EN 292-2
The Zargen press, model ZPM, is manufactured in accordance with the present state of technology and current
safety and technical directives. Still, there remain risks to the life and health of the operators or of third parties,
and damages to the machine and other material assets.
Other risks consists of:
-operation of the machine by unqualified personnel,
- operation of the machine without the required and recommended safety devices,
- additional people being in the work area of the operating machine,
- handling a machine that has not been properly secured and turned off,
- not maintaining the procedural instructions which are described in Section 7-0, which concerns
operating the ZPM,
- the malfunction of control elements.
These risks can be reduced if the operators and owners comply with Section 2-0 and Section 7-0.
2-004 Safety Devices
Safety devices and danger notices, etc. serve to ensure safety and may NOT, in any case, be removed or be
made inoperable.
- The pneumatic-filter-reducing regulator prevents the machine from overloading.
- The 2-handed pneumatic valve prevents an unintentional stroke disengagement or release.
Pneumatic diagram, Section 4-006.

2. SAFETY INFORMATION
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2-005 Description of Stickers
This sticker indicates conformity with the
European Community agreement.
Prohibitive sign: Only one person shall operate the
machine at a time.
Warning sign: anger of crushing. Keep hands or
other objects clear.
Operating instructions: Read information thoroughly.
2-006 Dangers and Safety Measures
Dangers Safety Measures
Forward feed mechanism no automatic forwarding feed movement
Risk of impact This is not applicable because the stroke motion
is slow.
Tool unit The forward feed for the stroke motion is activated
by non self-locking buttons with collar. This meets
the safety guidelines EN 294 with regard to the risks.
Control system non self-locking button with collar
unexpected stroke disengagement 2-handed safety control
Control system defect Use only authorized replacement parts

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3. DESCRIPTION OF PRODUCTS
Change-over inserts
Index stop
Front height stop

3. DESCRIPTION OF PRODUCTS
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3-001 Usage
The Zargen press ZPM is designed exclusively for pressing and inserting the Grass Zargen slide with a wood
back wall, a wood bottom and a wood front. Solid wood, other materials derived from wood, such as particle
board, M F-boards, glued and bonded woods, etc. can be used. The manufacturer guarantees smooth and
problem free operation for these usages with the machine. Violations or misuse may result in injuries to
the machine operators or to damages to the machine or work pieces.
3-002 Identification of Products
All machines are provided with an identification plate on which the manufactured year, the machine number and
model, as well as the required pneumatic pressure, are listed. There is also a sticker label on the machine frame
that has the machine identification.
3-003 Basic Equipment
The Zargen press ZPM , completely installed, consists of:
- a stabile durable machine frame,
- a rigid insertion unit, left,
- over the index stops, there is a movable insertion unit, right,
- complete pneumatic control system with 2-handed safety control system,
- complete operating instructions,
- tool kit, consisting of 13 mm and 17 mm open-ended fork wrench, an adjustment gauge for front stops and
one of each of these size Allen key wrenches: 2.5 mm, 3 mm, 4 mm, 5 mm, 6 mm.
3-004 Standard Accessories
Description Article Number
Front height stop ( back wall height stop) 88918
Index stop for drawer width 90651
Change-over insert for Zargen slide length 270 88910
Change-over insert for Zargen slide length 350 88911
Change-over insert for Zargen slide length 400 88912
Change-over insert for Zargen slide length 440 88913
Change-over insert for Zargen slide length 470 88914
Change-over insert for Zargen slide length 510 88915
Change-over insert for Zargen slide length 550 88916
3-005 Special Accessories
Various special accessories are available upon request.
For example: a fence for the Zargen press for the backside to prevent reaching into the ZPM.
Special index stops
Special front side stops

4. DESCRIPTION OF MACHINE COMPONENTS
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Illustration 4-001-01

4. DESCRIPTION OF MACHINE COMPONENTS
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4-001 Overview of numbered individual parts Illustration 4-001-01
1. Machine frame
2. Left hand lever
3. Right hand lever
4. Left insertion cylinder
5. Right insertion cylinder
6. Compressed air regulator
7. Left starting valve
8. Right starting valve
9. 2-handed safety control system
10. Pneumatic operating valve
11. Left unit carrier
12. Right unit carrier
13. Left carriage
14. Right carriage
15. Left compression slide
16. Right compression slide
17. Back wall dowel - compression die fence, left
18. Back wall dowel - compression die fence, right
19. Left change-over insert
20. Right change-over insert

4. DESCRIPTION OF MACHINE COMPONENTS
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Illustration 4-002-01
Illustration 4-002-02

4. DESCRIPTION OF MACHINE COMPONENTS
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4-002 Description of individual assembly parts Illustration 4-002-01 and 4-002-02
1. Insertion cylinder, diameter 120 stroke 60 mm
2. 2-handed control valve
3. 5/2 port directional control valve
4. Machine frame
5. Holding device for upper guiding roller
6. Star screw M8 X 20 - fastener back wall compression die fence
7. Back wall compression die fence
8. Set screw - setting the insertion depth of the back wall dowel
9. Last back wall height stop on change-over insert
10. Bumper bar - back wall support - change-over insert
11. Back wall height stop with retractable stop pin
12. Spacer profile - change-over insert
13. Clamp screw
14. Adjusting screw for bottom thickness
15. Front side stop
16. Compression die fence for front dowel
17. Toggle bar with starting valve
18. Press on rail
19. Unit carrier
20. Set collar Change-over from 6035 to 6036, 6136, 6236, 6436
21. Stop pin for front height stop - retractable
22. Front height stop
23. Stop bar for front height stops
24. Flap screws to adjust the front height stops
25. Adjusting screws for front angle
26. Carriage
27. Front support
28. Front side stop
29. Press on disk to set the bottom length

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4. DESCRIPTION OF MACHINE COMPONENTS
Illustration 4-004-01 Illustration 4-004-02 Illustration 4-004-03
Illustration 4-004-04 Illustration 4-004-05 Illustration 4-004-06

4. DESCRIPTION OF MACHINE COMPONENTS
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4-003 Description of Operating Elements
Toggle lever, left and right
The toggle lever is used to close and open the Zargen press.
Place all the individual parts in the Zargen press, which is in the open position.
Press all the individual parts, which comprise the complete drawer in the Zargen press, which is in the
closed position.
Take the finished drawer out of the Zargen press, which is in the open position.
Index pin
The index pin positions the machine for preset drawer widths.
Right and left start buttons
Operating both buttons, left and right, at the same time (within 0.5 second) begins the compression
operating process.
4-004 Functions of the ZPM - Producing Drawers with the ZPM Illustrations 4-004-01, 02, 03, 04, 05, 06
All machines manufactured since 1995 are equipped with a pneumatic 2-handed safety control system. The
compression cycle first begins when both start buttons are operated simultaneously (within 0.5 second). After
one of the start buttons is released, both compression slides return to their starting positions. The start buttons
may only be activated when the toggle lever is completely closed.
Sequence of the operating cycle:
- Pull the index pins. Move the right unit carrier to the drawer width’s corresponding index stop. Release
the index pins. (These must engage in the index stops).
- Open both toggle levers.
- Push the stop pin of the corresponding front height stop „1“ up.
- Push the stop pin of the corresponding back wall height stop „2“ (Illustration 4-004-01) up.
- Load the drawer front with the dowel bore holes up and the front lower edge towards the machine operator.
- Place the drawer bottom with the bottom groove towards the machine operator.
- Place the drawer back wall with the dowel bore holes up and the back wall lower edge
towards the machine operator (Illustration 4-004-02).
- Load both Zargen slides (Illustration 4-004-03).
- Close both toggle levers.
- Press both start buttons on the toggle levers (simultaneously within 0.5 seconds - 2-handed control system).
- Now the compression process begins.
Both compression slides move diagonally towards the bottom and the bottom grip devices are pressed
into the bottom groove.
After the bottom grip devices are pressed in, both compression slides move downward; the back wall
dowel - compression die fence presses on the back wall dowel; the front compression die fence
presses on both front dowels; the Zargen slide is pushed underneath in the bottom groove, until all the
dowels are completely pressed in. (Illustration 4-004-04).
- The compression process has ended. Release both start buttons.
- Wail until both compression slides have reached the highest position (Illustration 4-004-05).
- Open both toggle levers (Illustration 4-004-06).
- Remove the completely assembled drawer.
Note:
If the drawers to be pressed together are using the Grass Railing System 6100, we recommend mounting the
corresponding railing fasteners to the front and back wall before the front and back wall are placed in the
Zargen Press ZPM.

5. SHIPPING AND INSTALLATION OF MACHINES
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5-001 Shipping and Storage Requirements
The Zargen press ZPM is shipped unpacked. The machine is completely assembled.
Protect the unpacked machine during the shipping process and storage from moisture and humidity.
The machine can be transported by both transverse bars about 10 cm above the floor in the center of a
low lift platform truck. The storage temperature range is -20 degrees Celsius to +50 degrees Celsius.
Warning:
This machine’s center of gravity is quite high (see Illustration 5-001-01). During shipping there is the
risk
that the machine may fall over.
This machine must be secured against falling during shipping.
Whenever lifting or shipping the ZPM (with a low lift platform truck or a fork lift truck), extra care
and caution must be used.
about 950
aboutt
300
aboutt
540
= =
Center of gravity

5. SHIPPING AND INSTALLATION OF MACHINES
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5-002 Space and Environment Requirements
The necessary space requirements depend on the quantity of the available individual assembly components
and the quantity of the stored finished drawers.
The minimum depth dimensions required are about 200 cm.
The minimum width dimensions required are about 200 cm.
The machine must be kept in a dry room away from humidity and moisture.
The surrounding temperature of the operating machine should be between +10 degrees Celsius and +40
degrees Celsius.
The relative humidity should in the range of 10% to 80% and should be non condensing.
The machine may malfunction or become damaged with large deviations in extreme environmental conditions.
5-003 Assembly at the Final Installation Site
The Zarge press is shipped to its final installation site with a low lift platform truck or a fork lift truck. Once there,
the dual sided shipping security wood beams are dismantled. The machine is placed on the floor. Please make
sure the machine is on a level surface.
If need be, the machine frame can be leveled out under one of the 4 corners. We strongly recommend bolting
or screwing the machine to the floor.
Now both security bands (used for shipping safety), which hold the unit carriers to the machine frame, can be
removed.
Once the machine is installed at the final location, the pilot run operation can be initiated, according to
Section 6.
Note:
In order toa void the dangerous position behind the Zargen press, please comply with the following measures:
Recommended:
a) Place the Zargen press as closely to a wall as possible, or
b) Attach a closure on the side and behind the Zargen press. This is available as a special accessory from
Grass Inc.
Safely securing the ZPM is the responsibility of the Zargen press owner.
5-004 Requirements of Operating Personnel
This machine may only be operated by trained personnel that are familiar with operation of the machine. This
training may come from on-the-job training by a specialist or by thoroughly studying the operating instructions.
The operators must be mentally and physically capable of operating this machine. It is the machine
owner’s responsibility to ensure that the machine operators are capable and knowledgeable about using this
machine.
The machine operators must be responsible and not allow other persons near the machine when it is being
operated.
The machine owner is responsible for making sure compliance of these requirements are met.

6. START-UP
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6-001 Pneumatic connection
The Zargen press ZPM has a 2 meter long air hose that has a diameter of 6/3. A Euro-Quick coupler plug is
installed corresponding to the voltage in the destination country. See Section 6-002 on page 22 for the wiring
diagram.
Connection:
Caution:
If the machine is hooked up to pressure, both compression slides can move upward.
a) Lift the adjusting knob of the maintenance unit and turn counterclockwise.
b) Make the air pressure connection by means of a quick coupling or a shut-off valve with an exhaust. It
has to be connected so that the machine operator can disconnect the machine from the air pressure
system at anytime with a distance of maximum 3 meters.
c) Turn the regulator clockwise until the pressure gauge of the maintenance unit indicates about 5.5 - 6 bar
(0.55 - 0.6 MPa). Press the adjusting knob.
Caution: the compression slide can move up.
6-002 Pneumatic diagram of the ZPM
Posi. Model Description Function
1 Hoerb. MKL-08H Filter-pressure-reducer 1/4“ Pressure regulator and
including pressure gauge 1/8“ pneumatic draining
2. Festo SV3-M5-B 3/2 directional key valve M5 Starting valve, left
3. Festo SV3-M5-B 3/2 directional key valve M5 Starting valve, right
4. Bosch 0 820 223 501 2-handed control valve M5 Safety valve
5. Hoerb S8-561RF-1/8-2 Pneumatic 5/2 directional valve 1/8“ Operating valve
6. Grass T.1320.005.01 Pneumatic cylinder, Insertion cylinder,
diameter 120, stroke 40 left / right