Hafco Metalmaster GHD-45G User manual

GEAR HEAD DRILL
OPERATION MANUAL
Edition No : GHD45G001
Date of Issue : 10/2017
Model
GHD-45G

2
OPERATION MANUAL
NOTE:
In order to see the type and model of the machine, please see the
specication plate. Usually found on the back of the machine. See
example (Fig.1)
Fig.1
GEAR HEAD DRILL
MACHINE
GHD-45G
MODEL NO.
SERIAL NO.
DATE OF MANF.
NOTE:
This manual is only for your reference. Owing to the continuous improvement of the ma-
chine, changes may be made at any time without obligation or notice. Please ensure the local
voltage is the same as listed on the specication plate before operating this electric machine.
Distributed by
www.machineryhouse.co.nz
MACHINE DETAILS

OPTIMUM
MASCHINEN - GERMANY
Version 1.0.1 dated 2017-05-19Page 2 Translation of the original instructions
DH45GGB
Table of contents
1 Safety
1.1 Type plate .................................................................................................................................................5
1.2 Safety instructions (warning notes)...........................................................................................................6
1.2.1 Classification of hazards ...............................................................................................................6
1.2.2 Other pictograms...........................................................................................................................6
1.3 Intended use .............................................................................................................................................7
1.4 Reasonably foreseeable misuse...............................................................................................................8
1.4.1 Avoiding misuse ............................................................................................................................8
1.5 Possible dangers caused by the geared drill ............................................................................................8
1.6 Qualification of personnel .........................................................................................................................9
1.6.1 Target group..................................................................................................................................9
1.6.2 Authorized persons .....................................................................................................................10
1.7 User positions .........................................................................................................................................10
1.8 Safety measures during operation..........................................................................................................11
1.9 Safety devices ........................................................................................................................................11
1.10 Safety check ...........................................................................................................................................11
1.11 Emergency-stop push button..................................................................................................................12
1.11.1 Main switch..................................................................................................................................12
1.11.2 Drill chuck guard..........................................................................................................................12
1.12 Personal protective equipment ...............................................................................................................13
1.13 Safety during operation...........................................................................................................................13
1.14 Safety during maintenance.....................................................................................................................14
1.14.1 Disconnecting and securing the geared drill ...............................................................................14
1.15 Using lifting equipment ...........................................................................................................................14
1.15.1 Mechanical maintenance.............................................................................................................14
1.16 Accident report........................................................................................................................................14
1.17 Electrical system.....................................................................................................................................14
1.18 Inspection deadlines...............................................................................................................................15
2 Technical specification
2.1 Emissions ...............................................................................................................................................17
2.2 Dimensions .............................................................................................................................................19
3 Delivery, internal transport, unpacking
3.1 Delivery...................................................................................................................................................20
3.2 Internal transport.....................................................................................................................................20
3.3 Unpacking...............................................................................................................................................21
3.4 Lifting the machine..................................................................................................................................21
3.5 Installation requirements.........................................................................................................................22
3.5.1 Foundation and ground ...............................................................................................................22
3.6 Fixing ......................................................................................................................................................22
3.6.1 Assembly drawing .......................................................................................................................23
3.7 Lubrication ..............................................................................................................................................23
3.7.1 Gear ............................................................................................................................................24
3.7.2 Coolant system............................................................................................................................24
3.8 First commissioning ................................................................................................................................24
3.9 Electrical connection...............................................................................................................................25
3.9.1 Connecting the optional foot switch.............................................................................................26
3.9.2 Warming up the machine ............................................................................................................26
4Operation
4.1 Control and indicating elements .............................................................................................................27
4.2 Control panel ..........................................................................................................................................28
4.2.1 Drill depth stop ............................................................................................................................28

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4.3 Switching on the machine ...................................................................................................................... 28
4.4 Switching off the machine ...................................................................................................................... 29
4.4.1 Gear selector switch.................................................................................................................... 29
4.5 Spindle quill feed .................................................................................................................................... 29
4.5.1 Manual spindle sleeve feed......................................................................................................... 29
4.5.2 Automatic spindle sleeve feed .................................................................................................... 29
4.6 Disassembly, assembly of drill chucks and drill bits ............................................................................... 29
4.6.1 Use of the drill chuck................................................................................................................... 29
4.6.2 Disassembly with integrated drill drift.......................................................................................... 29
4.6.3 Fitting the drill chuck ................................................................................................................... 30
4.7 Coolant equipment ................................................................................................................................. 30
4.8 Footswitch - Rotation reversal................................................................................................................ 30
5 Determining the cutting speed and the speed
5.1 Table cutting speeds / infeed ................................................................................................................. 31
5.2 Speed table ............................................................................................................................................ 31
5.3 Examples to calculatory determine the required speed for your drilling machine .................................. 33
6 Maintenance
6.1 Safety ..................................................................................................................................................... 34
6.1.1 Preparation.................................................................................................................................. 34
6.1.2 Restarting.................................................................................................................................... 34
6.2 Inspection and maintenance .................................................................................................................. 35
6.3 Repair..................................................................................................................................................... 39
6.3.1 Customer service technician....................................................................................................... 39
6.4 Cooling lubricants and tanks .................................................................................................................. 40
6.4.1 Inspection plan for water-mixed cooling lubricants ..................................................................... 41
7 Malfunctions
8 Ersatzteile - Spare parts
8.1 Ersatzteilbestellung - Ordering spare parts ............................................................................................ 45
8.2 Elektrische Ersatzteile - Electrical spare parts ....................................................................................... 45
8.3 Schaltplan - Wiring diagram ................................................................................................................... 45
8.4 DH45G ................................................................................................................................................... 46
8.5 Schaltplan - Wiring diagram 1-4 ............................................................................................................. 56
8.6 Schaltplan - Wiring diagram 2-4 ............................................................................................................. 57
8.7 Schaltplan - Wiring diagram 3-4 ............................................................................................................. 58
8.8 Schaltplan - Wiring diagram 4-4 ............................................................................................................. 59
9 Appendix
9.1 Copyright ................................................................................................................................................ 63
9.2 Terminology/Glossary ............................................................................................................................ 63
9.2.1 Change information operating manual........................................................................................63
9.3 Liability claims/warranty ......................................................................................................................... 64
9.4 Storage................................................................................................................................................... 65
9.5 Advice for disposal / Options of reuse:................................................................................................... 65
9.5.1 Decommissioning........................................................................................................................ 66
9.5.2 Disposal of new device packaging .............................................................................................. 66
9.5.3 Disposal of the old device ........................................................................................................... 66
9.5.4 Disposal of electrical and electronic components ....................................................................... 66
9.5.5 Disposal of lubricants and coolants............................................................................................. 67
9.6 Disposal via municipal collection facilities .............................................................................................. 67
9.7 RoHS, 2011/65/EU................................................................................................................................. 67
9.8 Product follow-up.................................................................................................................................... 67

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DH45G_GB_preface.fm
Preface
Dear customer,
Thank you very much for purchasing a product made by OPTIMUM.
OPTIMUM metal working machines offer a maximum of quality, technically optimum solutions and convince
by an outstanding price performance ratio. Continuous enhancements and product innovations guarantee
state-of-the-art products and safety at any time.
Before commissioning the machine please thoroughly read these operating instructions and get familiar with
the machine. Please also make sure that all persons operating the machine have read and understood the
operating instructions beforehand.
Keep these operating instructions in a safe place nearby the machine.
Information
The operating instructions include indications for safety-relevant and proper installation, operation and main-
tenance of the machine. The continuous observance of all notes included in this manual guarantee the safety
of persons and of the machine.
The manual determines the intended use of the machine and includes all necessary information for its eco-
nomic operation as well as its long service life.
In the paragraph "Maintenance" all maintenance works and functional tests are described which the operator
must perform in regular intervals.
The illustration and information included in the present manual can possibly deviate from the current state of
construction of your machine. Being the manufacturer we are continuously seeking for improvements and
renewal of the products. Therefore, changes might be performed without prior notice. The illustrations of the
machine may be different from the illustrations in these instructions with regard to a few details. However,
this does not have any influence on the operability of the machine.
Therefore, no claims may be derived from the indications and descriptions. Changes and errors are reserved
!
Your suggestion with regard to these operating instructions are an important contribution to optimising our
work which we offer to our customers. For any questions or suggestions for improvement, please do not hesi-
tate to contact our service department.
If you have any further questions after reading these operating instructions and you are not able to
solve your problem with a help of these operating instructions, please contact your specialised
dealer or directly the company OPTIMUM.
Optimum Maschinen Germany GmbH
Dr.- Robert - Pfleger - Str. 26
D-96103 Hallstadt
Fax (+49)0951 / 96 555 - 888
Email: in[email protected]
Internet: www.optimum-maschinen.de

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1 Safety
Glossary of symbols
This part of the operating instructions
explains the meaning and use of the warning notes included in these operating instructions,
defines the intended use of the geared drill,
points out the dangers that might arise for you or others if these instructions are not
observed,
informs you about how to avoid dangers.
In addition to these operation instructions, please observe
the applicable laws and regulations,
the statutory provisions for accident prevention,
the prohibition, warning and mandatory signs as well as the warning notes on the geared
drill.
Always keep this documentation close to the geared drill.
1.1 Type plate
INFORMATION
If you are unable to rectify an issue using these operating instructions, please contact us for
advice:
Optimum Maschinen Germany GmbH
Dr. Robert-Pfleger-Str. 26
D-96103 Hallstadt, Germany
Email: [e-mail]
provides further instructions
calls on you to act
listings

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1.2 Safety instructions (warning notes)
1.2.1 Classification of hazards
We classify the safety warnings into different categories. The table below gives an overview of
the classification of symbols (ideogram) and the warning signs for each specific danger and its
(possible) consequences.
1.2.2 Other pictograms
Symbol Alarm expres-
sion Definition / consequence
DANGER! Impending danger that will cause serious injury or death to people.
WARNING! A danger that can cause serious injury or death.
CAUTION!
A danger or unsafe procedure that can cause personal injury or damage to
property.
ATTENTION!
Situation that could cause damage to the geared drill and product, as well as
other types of damage.
No risk of injury to persons.
Information
Practical tips and other important or useful information and notes.
No dangerous or harmful consequences for people or objects.
In case of specific dangers, we replace the pictogram with
or
general danger with a warning of injury to hands, hazardous
electrical voltage,
rotating parts.
Warning: danger of
slipping!
Warning: risk of stumbling! Warning: hot surface! Warning: biological hazard!
Warning: automatic start-
up!
Warning: tilting danger! Warning: suspended loads! Caution, danger of
explosive substances!

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1.3 Intended use
WARNING!
In the event of improper use of the geared drill
will endanger personnel,
will endanger the machine and other material property of the operating company,
the correct function of the geared drill may be affected.
The geared drill is designed and manufactured to be used in a non-explosive environment. The
geared drill is designed and manufactured for holes in cold metals or other non flammable
materials or that not constitute a health hazard using a rotating filing-stripping tool that has a
number of grooves for collecting the filings.
If the geared drill is used in any way other than described above, modified without authoriza-
tion of Optimum Maschinen Germany GmbH, then the geared drill is being used improperly.
We will not be held liable for any damages resulting from any operation which is not in accord-
ance with the intended use.
We expressly point out that the guarantee or CE conformity will expire due to any constructive
technical or procedural changes which had not been performed by the company Optimum
Maschinen Germany GmbH.
It is also part of intended use that
observe the limits of the geared drill,
the operating manual is observed,
the inspection and maintenance instructions are observed.
 "Technical specification“ on page 16
WARNING!
Extremely severe injuries.
It is forbidden to make any modifications or alternations to the operation values of the
geared drill! They could endanger the personnel and cause damage to the geared drill.
Switching on forbidden! Do not climb onto the
machine!
Read the operating
instructions before
commissioning!
Pull out the mains plug!
Wear protective glasses! Wear protective gloves! Wear safety shoes! Wear a protective suit!
Use ear protection! Only switch during
standstill!
Protect the environment! Contact address

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1.4 Reasonably foreseeable misuse
Any use other than that specified under "Intended use" or any use beyond that described will be
deemed non-intended use and is not permissible.
Any other use must be discussed with the manufacturer.
It is only allowed to process metal, cold and non-inflammable materials with the geared drill.
In order to avoid misuse, it is necessary to read and understand the operating instructions
before first commissioning.
Operators must be qualified.
1.4.1 Avoiding misuse
Use of suitable cutting tools.
Adapting the speed adjustment and feed to the material and workpiece.
Clamp workpieces firmly and free of vibration.
ATTENTION!
The workpiece is always to be fixed by a machine vice, jaw chuck or by another
appropriate clamping tool such as for the clamping claws.
WARNING!
Risk of injury caused by flying workpieces.
Clamp the workpiece in the machine vice. Make sure that the workpiece is firmly clamped in the
machine vice and that the machine vice is firmly clamped onto the machine table.
Use cooling and lubricating agents to increase the durability of the tool and to improve the
surface quality.
Clamp the cutting tools and workpieces on clean clamping surfaces.
Sufficiently lubricate the machine.
Set the bearing clearance and guides correctly.
Recommendations:
Insert the drill in a way that it is exactly positioned between the three clamping jaws of the
quick action chuck.
When drilling, make sure that
the suitable speed is set depending on the diameter of the drill,
the pressure must only be such that the drill can cut without load,
if there is too much pressure, the drill will wear quickly and may even break or jam in the
borehole. If the drill jams, immediately stop the main motor by pressing the emergency stop
switch,
use commercial cooling/lubricating agents for hard materials, e.g. steel and
generally always back the spindle out of the workpiece while it is still turning.
1.5 Possible dangers caused by the geared drill
The geared drill was built using state-of-the-art technology.
Nevertheless, there is a residual risk as the geared drill operates with
at high speeds,
with rotating parts,
electrical voltage and currents.
We have used design and safety engineering to minimize the health risk to personnel resulting
from these hazards.

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If the geared drill is used and maintained by personnel who are not duly qualified, there may be
a risk resulting from incorrect or unsuitable maintenance of the geared drill.
INFORMATION
Everyone involved in the assembly, commissioning, operation and maintenance must
be duly qualified,
and strictly follow these operating instructions.
In the event of improper use
there may be a risk to personnel,
there may be a risk to the machine and other material values,
the correct function of the geared drill may be affected.
Always disconnect the geared drill if cleaning or maintenance work is being carried out, or is no
longer in use.
WARNING!
The geared drill may only be operated with functional safety devices.
Disconnect the geared drill immediately, whenever you detect a failure in the safety
devices or when they are not fitted!
All additional devices installed by the operator must be equipped with the stipulated
safety devices. This is your responsibility as the operator!
 "Safety devices“ on page 11
1.6 Qualification of personnel
1.6.1 Target group
This manual is addressed to
the operating companies,
the operators,
the maintenance personnel.
Therefore, the warning notes refer to both, operation and maintenance personnel of the geared
drill.
Determine clearly and explicitly who will be responsible for the different activities on the geared
drill (operation, setting up, maintenance and repair).
Unclear responsibilities constitute a safety risk!
Always disconnect plug of the geared drill from the electrical power supply. This will prevent it
from being used by unauthorized persons.
The qualifications of the personnel for the different tasks are mentioned below:
Operator
The operator is instructed by the operating company about the assigned tasks and possible
risks in case of improper behaviour. The operator may only carry out tasks that exceed normal
operation if this is stated in these instructions and the operating company has explicitly
entrusted him with the task.
Qualified electrician
With professional training, knowledge and experience as well as knowledge of respective
standards and regulations, qualified electricians are able to perform work on the electrical sys-
tem and recognise and avoid any possible dangers.
Qualified electricians have been specially trained for the working environment, in which they are
working and know the relevant standards and regulations.