Meusburger GMT 6000 User manual

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Documentation
DPM
Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
(Changes reserved!)
Approval no. 300.00.00550
Operating Manual
GMT 6000 - Precision cutting machine

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Documentation
DPM
Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
Preface
The information contained in this manual ensures that the dpm ejector
cutting unit is operated safely, properly and efficiently. Following the
explanations, notices and regulations:
prevents hazards and faults,
reduces repair costs and downtimes
increases reliability and the service life
of the machine. The operator must ensure that persons tasked with
using, maintaining and repairing the dpm ejector cutting unit read the
manual. The manual must be kept at hand in the place where the
machine is used.
Not being familiar with or not observing this manual can give rise
to hazards to persons!
This manual must be read carefully before the ejector cutting unit
is commissioned. The instructions, particularly the safety
instructions, must be followed!
This manual applies only to the "ejector cutting unit“ indicated on the
cover page and specified in the section on "Suitability". Before it is used
outside its described field of application, it is essential to consult
dpm Daum + Partner Maschinenbau GmbH
Am Lauerbühl 2
D - 88317 Aichstetten, Germany
Tel. [phone] Fax. [phone]
Otherwise any warranty, liability and accessory liability claims shall be
void.
Copyright © 13 April 2017 10:00:43 by dpm Daum + Partner
Maschinenbau GmbH Realisation: dpm Daum + Partner Maschinenbau
GmbH
All rights to this manual are reserved, particularly the right of
reproduction and distribution as well as translation. No part of the
manual may be reproduced or electronically processed, copied or
distributed in any form (by copying, on microfilm or by another means)
without the prior written permission of Daum + Partner.
Issue: 13 April 2017 10:00:43 Author: M. Kieble/EW

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Documentation
DPM
Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
Contents
Preface.................................................................................................................................................2
Contents.............................................................................................................................................3
1. Notes about the operating manual............................................................................................5
1.1 Note, terms, symbols..............................................................................................................5
1.2 Pictograms............................................................................................................................6
2. Correct use in accordance to the instructions (intended use)................................................7
2.1 Use of the machine ................................................................................................................7
3. Safety..........................................................................................................................................8
3.1 Safety directives and regulations............................................................................................8
3.2 Safety hazards.......................................................................................................................8
3.3 Safety symbols and safety markings of the ejector cutting unit..............................................10
4. Overall view..............................................................................................................................11
4.1 Complete control unit..........................................................................................................13
4.2 Complete linear unit............................................................................................................14
4.3 Clamping prism ..................................................................................................................15
4.4 Support prism.....................................................................................................................16
4.5 Length adjustment ..............................................................................................................17
4.6 Pivoting motor base.............................................................................................................18
4.7 Grinding spindle / cutting wheel...........................................................................................20
4.8 Grinding spindle / cup wheel................................................................................................21
4.9 Rocker bearing....................................................................................................................22
4.10 Spindle bearing...................................................................................................................23
4.11 Technical Data....................................................................................................................24
5. Operation..................................................................................................................................25
5.1 Setting up the machine: .......................................................................................................25
5.2 Machine connections:..........................................................................................................26
5.3 Controls and displays ..........................................................................................................27
5.4 Switching on .......................................................................................................................30
5.5 Switching off.......................................................................................................................30
5.6 Dressing the grinding wheel.................................................................................................30
5.7 Inserting a workpiece ..........................................................................................................30
5.8 Referencing "obtaining zero position"..................................................................................31
5.9 Cut-off grinding..................................................................................................................31

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Documentation
DPM
Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
5.10 Surface grinding..................................................................................................................31
5.11 Emergency stop...................................................................................................................32
5.12 Acknowledge the emergency stop.........................................................................................32
6. Care and maintenance.............................................................................................................33
7. Spare parts list.........................................................................................................................38
8. Accessories..............................................................................................................................40
9. Declaration of Conformity .......................................................................................................42
Fault report fax.................................................................................................................................43

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Documentation
DPM
Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
1. Notes about the operating manual
1.1 Note, terms, symbols
Safety Safety regulations for safe, risk-free use of the ejector cutting unit.
Operation Information about the suitability, use, function, operation, variants
and accessories.
Commissioning Information on the operation of the machine
Control Explanation of the control elements, description of handling.
Maintenance Work that must be done for the purpose of safe operation, to
maintain functional capability and to avoid hazards or faults.
Faults Explanation of the causes of faults and how to remedy them.
Appendix Illustrations, standard maintenance instruction, sample of an
inspection report in accordance with the directives of the
employer's liability insurance association.

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Documentation
DPM
Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
1.2 Pictograms
The machine and this manual carry labels that warn of hazards,
stipulate or command particular actions and point out special
information. It is essential to follow the notices and regulations that
these highlight!
Danger!
Warning about a dangerous situation. There is a direct risk of a serious
accident is the regulations and instructions are not observed!
Warning!
Warning about a possibly dangerous situation! Not following the instruction
can give rise to accident risks!
Caution!
Warning about a possibly dangerous situation or damage. Not following
the instructions can give rise to accident risks or damage to the ejector
cutting unit.
Command!
A particular action is stipulated! Not following the command can give rise
to a dangerous situation or damage!

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Documentation
DPM
Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
Note!
Supplementary information about particular circumstances, explanations,
descriptions, cross references, explanations of special activities or
functional processes. Not following the instruction can give rise to
damage. There is no accident risk.
2. Correct use in accordance to the instructions (intended use)
2.1 Use of the machine
Machine tool for cutting and surface grinding of cylindrical and stepped ejector pins, flat ejectors,
profile stamps, punching dies, ejector bushes etc. The grinding wheels are driven by two three-phase
asynchronous motors with squirrel-cage rotors by a toothed belt drive. The force exerted by the
workpiece on the grinding wheel is always radial. The cup wheel can be aligned by a puller diamond
and set with an adjusting screw until the wear limit is reached. The workpiece is held in place by a
spring clamping prism and positioned with a stop. A linear unit with screw spindle adjustment and
visual digital output facilitates the exact (0.01 mm) positioning/advance of the workpiece before
cutting (separation) and subsequent surface grinding.

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Documentation
DPM
Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
3. Safety
3.1 Safety directives and regulations
The following general safety regulations must be followed:
Commissioning, operation and maintenance only after briefing and
instruction by the owner and knowledge of the operating manual.
Commissioning, operation and maintenance only by trained and
qualified personnel (protective goggles and safety shoes are
mandatory)
When switching on the machine, the direction of rotation of the cup
wheel must be clockwise and that of the cutting wheel must be counter-
clockwise, see also instructions under 5.2 Connections of the machine
Only switch on once you have checked the safety devices function
correctly.
Do not tamper with any safety devices or bypass, deactivate or
remove them.
The accident prevention regulations must be observed, and all working
methods that can jeopardise work safety are prohibited.
3.2 Safety hazards
Potential hazards if the operating manual is not followed:

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Documentation
DPM
Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
If the machine is not operated, maintained or repaired in accordance
with the safety regulations, or if it is operated improperly or misused, the
result is
•Hazards to the health of operating personnel,
•Hazards to the machineand other property belonging to the operator
•Impairment of the machine's efficient functioning.
If the regulations laid down in the operating manual are not observed, the
manufacturers shall not be liable for the resulting damage and consequential
losses!
Safety hazards can occur from:
•Working at the machine without a protective cover on the grinding wheel,
(unauthorized changes to the safety devices are not permitted).
•The two grinding wheels rotating in the incorrect direction
•The rotating grinding wheels when working at the machine (there is a risk of
clothes, long hair or gloves being pulled into the machine).
•Force applied to the grinding wheels in the axial direction. (There is a risk of
breakage of the grinding wheels).
•Operating the rocker mechanism (there is a risk of crushing between the
rocker and its base).
•Working on the machine without protective goggles (danger from flying metal
chips and grinding dust).
•Removing the cut-off workpiece parts (risk of burning)
•Parts can be thrown out if the grinding wheels are defective. (risk of injury).
•Inserting the shaft into the spring prism (risk of crushing fingers).
•Risk from electrostatic charging of components, personnel touching contact
charged parts.
•Working at the electronic box or motor housing by touching live parts during
operation. Risk from damaged lines or cables. Only trained electricians may
carry out such work.
•Do not operate the machine in hazardous areas.
•Switching on the machine with the workpiece inserted

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Documentation
DPM
Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
•Transportation of the machine - personal safety measures appropriate to the
total weight of the machine must be taken. Additionally, the personnel must
be informed about any loose or moving parts of the machine before
transport. (Only trained and instructed personnel are permitted to transport
the machine).
•The main switch must be switched off for maintenance, inspection or
cleaning of the machine.
3.3 Safety symbols and safety markings of the ejector cutting unit
1
Mandatory
instruction
Disconnect first, then work on the electrical
installation.
2
Mandatory
instruction Wear ear protection
3
Mandatory
instruction
Wear protective goggles!
4
Mandatory
instruction
First read the operating manual, then activate!
5
Warning
There is the risk of crushing at the clamping device
of the shaft and the rocker mechanism
6
Warning
There is a risk of electric shock

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Documentation
DPM
Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
4. Overall view
1) 300.00.00398 (1x)
Base 5) 060.30.905 (1x) Glass scale MKT 37 9) 300.00.00392 (1x) Disc cover 13) 050.01.2971 Cup wheel
2) 300.00.00370 (1x)
Complete control cabinet
6) 300.00.00174 (1x)
Longitudinal adjustment (cup
wheel)
10) 300.00.00392 (1x)
Disc cover 14) 050.01.2972 Cutting wheel
3) 300.00.00403 (1x)
Linear unit 7) 050.01.2744 (1x) Handle 11) 300.00.00387 (1x) Holding rail for handle
4) 300.00.00462 (1x)
Cover
8) 300.00.00390 (1x)
Cover for complete grinding
wheel
12) 050.01.2953
Insulation for cover
2
7/11
6
3 1 9
8
4/12
5
1013
14

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Documentation
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Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
15) 050.01.2750 (1x)
Corrugated pipe fitting 90° 19) 300.00.00433 (1x) Complete drive console 23) 300.00.00437 (2x) Bracket
16) 050.01.2886 (4x)
Rubber-metal stop 20) 300.00.00452 (1x) Spring retainer, long 24) 300.00.00451 (1x) Spring retainer, short
17) 300.00.00359 (1x)
Adjustable spindle mount 21) 050.01.2928 (2x) Pressure spring 25) 300.00.00372 (2x) Adjusting block
18) 060.80.279 (1x)
Counter nut M32x1.5 22) 300.00.00436 (2x) Spring bearing
15/18
16 19
17
20/21/22/23
24 25

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Documentation
DPM
Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
4.1 Complete control unit
1) 300.00.00355 (1x)
Bottom cover 9) 300.00.00360 (1x) Control cabinet housing 17) 060.80.008-200 (1x) DIN rail 35x7.5 25) 060.72.622 (2x) End clamp TS 35
2) 300.00.00367 (1x)
Electrics box cover 10) 060.08.351 (1x) Mounting case, angled 18) 060.40.2812 (1x) 3-pin circuit breaker
26) 060.72.605 (2x)
4-wire circuit terminal
2.5mm²
3) 050.01.2750 (1x)
Corrugated pipe fitting 90°
11) 060.02.588 (1x)
Emergency stop mushroom
pushbutton
19) 060.07.009 (1x)
Safety relay 27) 060.72.606 (2x) Baffle plate, grey
4) 060.07.005 (3x)
Illuminated toggle switch,
green
12) 060.30.904 (1x)
Innova display 20) 060.07.015 (3x) Sirius motor starter
28) 060.72.604 (2x)
4-wire circuit terminal
2.5mm², grey
5) 060.80.29501 (1x)
Cable gland 13) 300.00.00368 (1x) El. box cover 21) 060.40.252 (1x) 1-pin circuit breaker 29) 060.72.623 (1x) Group tag holder
6) 060.08.716 (1x)
CEE plug 14) 060.07.012 (1x) Main / emergency-stop switch 22) 300.00.00426 (1x) Operating panel, angled
7) 050.01.2751 (1x)
Corrugated pipe PUR NW 29 15) 060.07.006 (1x) Illuminated pushbutton, blue 23) 060.80.29521 (1x) 10mm cable grommet
8) 060.04.031 (4x)
Tag labelling 16) 060.80.279 (1x) Counter nut M32x1.5 24) 060.07.016 (1x) 3-phase busbar
2/
13
12
3/
7/
16
18 19 20
25/
26/
27/
28/
29
15
11
14
4
8
1
10
6
5/
23
9
22
17
24
23

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Documentation
DPM
Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
4.2 Complete linear unit
1) 300.00.00382 (1x)
Clamping prism 7) 050.01.2713 (1x) Clamping lever 13) 050.01.2718 (4x) Ball lining Ø16
2) 300.00.00401 (1x)
Support prism
8) 300.00.00379 (1x)
Carriage guide bracket, outer
part
14) 050.01.2715 (1x)
Hardened precision shaft
Ø12h6
3) 300.00.00173 (1x)
Carriage base 9) 300.00.00174 (1x) Length adjustment
15) 050.01.2716 (1x)
Hardened precision shaft
Ø8h6
4) 300.00.00386 (1x)
Monitoring car holder 10) 300.00.00466 (1x) Shaft for length adjustment 16) Threaded pin (1x) ISO 4026-M6x16
5) 300.00.00166 (1x)
Carriage face plate
11) 300.00.00009 (1x)
Carriage guide bracket, inner
part
17) Hardened cylinder pin (1x)
ISO 8734-8x50
6) 300.00.0456 (1x)
Stop part
12) 050.01.2714 (2x)
Hardened precision shaft
Ø16h6
18) Threaded pin (6x)
ISO 4026-M6x8
5
2 9
15 810 11
14 12
1
3
6
16
17 18
7
4
13

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DPM
Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
4.3 Clamping prism
1) 300.00.00380 (1x)
Clamping prism base plate 5) 050.01.2770 (1x) Dressing diamond 9) Hardened cylinder pin (2x) ISO 8734-5x24
2) 300.00.00162 (1x)
Push-pull device guide 6) 050.01.2712 (1x) Cone handle 10) Hardened cylinder pin (1x) ISO 8734-5x10
3) 300.00.00161 (1x)
Push-pull device 7) 300.00.00036 (1x) Lever 11) Threaded pin (2x) ISO 4026-M5x16
4) 300.00.00163 (1x)
Support 8) 050.01.2892 (1x) Control spring Ø10x35.3xØ1.4
7 9 11
8
1
234
5
6
10

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DPM
Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
4.4 Support prism
1) 300.00.00402 (1x)
Support prism plate 3) Hardened cylinder pin (1x) ISO 8734-6x20
2) 050.01.2718 (2x)
Bushing
3
2
1

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DPM
Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
4.5 Length adjustment
1
1) 300.00.00175 (1x)
Adjustment bush 5) Retaining ring (1x) DIN 471 - 15x1 9) Retaining ring (1x) DIN 472 - 15x1
2) 300.00.00011 (1x)
Support
6) Axial deep groove ball bearings
(2x)
050.31.910 (Ø15 x Ø28 x 9)
10) 050.01.2717 (1x)
Stopper
3) 300.00.00014 (1x)
Washer disc
7) 050.01.2899 adjusting washer
(1x)
Ø15 x Ø28 x 1
4) 300.00.00396 (1X)
Washer 8) Threaded pin (3x) ISO 4026-M4x4
3
5
6
7
2
4
9
10
8
For cup wheel
adjustment

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Documentation
DPM
Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
4.6 Pivoting motor base
1) 300.00.00409 (1x)
Cutting wheel grinding spindle 7) 300.00.00194 (1x) Belt wheel T5/Z72 13) 300.00.00352 (1x) Adjustment bracket
2) 300.00.00407 (1x)
Cup wheel grinding spindle 8) 300.00.00186 (1x) Belt wheel T5/Z48 14) 300.00.00412 (1x) Stop ring
3) 060.07.051 (1x)
Three-phase asynchronous
motor
0.75 kW
9) 300.00.00427 (1x)
Mounting flange for motor,
small
15) 300.00.00423 (1x)
Perforated sheet
4) 060.07.050 (1x)
Three-phase asynchronous
motor
0.37 kW
10) 300.00.00428 (1x)
Mounting flange for motor,
large
16) 300.00.00063 (1x)
Positioning/advance holder
5) 050.01.2747 (1x)
Toothed belt T5 Z78 11) 300.00.00195 (1x) Connection plate 17) 300.00.00235 (1x) Motor cover
6) 050.01.2746 (1x)
Toothed belt T5 Z90 12) 300.00.00187 (1x) Connection plate
18) 050.01.2748 (2x)
Scraper Ø40xØ48.6x7
19) 300.00.00094 (1x)
Pressure spring Ø14 x 1 x 160
14 2
3
5
6
7
9
10 12
11
13
8
4
1
15
16
17

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DPM
Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
Info! M6 bolts glued with VBA 2M70 (Meusburger)!
19
18

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Documentation
DPM
Operating manual for precision cutting machine
Approved on: 23/02/2017 Approved by: M. Kieble
4.7 Grinding spindle / cutting wheel
1) 300.00.00408 (1x)
Grinding spindle sleeve 5) 300.00.00050 (1x) Disc flange, inside 9) 300.00.00052 (1x) Threaded ring
2) 300.00.00048 (1x)
Grinding spindle shaft 6) 300.00.00055 (1x) Washer 10) 300.00.00182 (1x) Toothed belt pulley T5 Z19
3) 300.00.00053 (1x)
Spacer sleeve 7) Fitting key (1x) DIN 6885 A4x4x18 11) Cylinder head bolt ISO 4762 M6x16-12.9 (1x)
4) 300.00.00393 (1x)
Clamping nut
8) 050.31.015 (2x) deep groove
ball bearings
DIN 625 SKF 6001-2RS1
10
1
2 9
5 4
6 7 8 3 11