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MILLRITE
MAINTENANCE INSTRUCTIONSAND PARTS LIST
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MILL SAFETY INSTRUCTIONS
GROUNDING THE MILL: Make certain that the machine frame is electrically grounded and thata grounding lead is included in the incoming electrical service. In cases where a cord and plug areused, make certain that the grounding lug connects to a suitable ground. Follow the grounding pro-cedure indicated by the National Electric Code.
EYE SAFETY: Wear an approved safety face shield, goggles or glasses to protect eyes when operat-ing the Mill.
PERSONAL PROTECTION: Before operating the machine, remove tie, rings, watch and other jewelry
and roll up sleeves above the elbow. Remove all outer loose clothing and confine long hair. Protect-ive type foot wear should be worn. Hearing protectors should be used where noise exceeds the levelof exposure allowed in Section t9t0.95 of the OSHA regulations. DO NOT WEAR GLOVES.
WORK AREA: Keep the floor around the machine clean and free of tools, tooling, stock, chips andother foriegn material, and oil, grease or coolant to minimize the danger of tripping or slipping. Besure the machine is free of chips, tools, and everything else not required for the task to be per-formed. Powermatic Burke recommends the use of anti-skid floor strips on the floor area where theoperator normally stands and that each machine's work area be marked off. Make certain the workarea is well lighted and ventilated. Provide for adequate work space around the machine.
5. DISCONNECT Machine electrics before any maintenance is performed. All maintenance and repairwork should be performed only by someone qualified to do so.
REPLACEMENT PARTS: Use only Powermatic Burke or factory authorized replacement parts andaccessories; otherwise, the warranty and guarantee will be null and void.
HAND SAFETY: Keep hands away from the cutting tool and work area when the machine is underpower.
MACHINE ADJUSTMENTS: Make all machine adjustments with power off except speed on a variablespeed model.
AVOID ACCIDENTAL STARTING: Make certain the motor switch is in the off position beforeconnecting power to the machine.
LIGHTING: Be sure the machine area is well lighted and ventilated. Follow the requirements of theOSHA regulations.
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SPECIFICATIONS
Spindle:Taper. R-8 (standard), No. 9 B & S, No. 2 Morse, No. 3 Morse, No. 30 NSSpeed'(A) Step-Pulley Model (RPM)
(1) with l/2 HP Gearmoror . . z s,r3o,zrs,3so,6go,10g0(2) With 3/4HP Gearmoror . . . 6S,tOS,lgO,ZgO,575,g60
Or . . . . . . . 130 ,215 ,360 ,580 ,1150 ,1720Or . . . . . . . 195 ,325 ,545 ,820 ,1730 ,2590Or . . . . . . 260 ,435 ,225 ,1160 ,2300 ,3440
(3 ) w i t h 1HP90oRPMMoto r . . . . . . . . 19o ,32o ,530 ,850 ,1680 ,2s20(4 ) W i th lHP1200RPMMoto r (s tandard ) . . . . . . . 26O,435 ,725 ,1 t60 ,23O0,3440(5) With I HP 1800 RPM Motor .390,660,995,1760,3490,5220
(B) Variable-Speed Model (RPM Range)(1) With 1 HP 900 RPM Motor (standard) . .2TS to 2250(2) With 1 HP 1200 RPM Motor. . . . . 350 to 3000(3) With 1 HP 1800 RPM Motor 500 to 4500
Table:Size of working surface . . . . 7" x 27" (177.8mm x 685.8mm) (standard)
8" x 32" (2O3.2mm x 812.8mm)8" x 36" (203.2mm x 914.4mm)
T-Slots, Number and size. Three, lL/16" (17.45mm) Wide, 2-l/8" (53.98mm) Between slotsDials Graduation:
(A) Inch (standard) . ..001" (.03mm)(B) Metric.(C) Inch/Metr ic . . . . . .001"/( .02mm)
Range:Longitudinal table travel:
(A) 7" x 27" Table (standard) . . 16" (406.4mm) (manual) (standard). . 14" (355.6mm) (powerfeed)
(B) 8" x 32" Table. . . . .21" (533.4mm) (manual)
(C)'b;"* l?;''i"ur.. : : : : : : : : : : : : : : : : : : : . : : : : : : . : : : : : . : : : : : : : .:?'.' .'i.3t#?I$,Xh'ji. . 23" (584.2mm) (powerfeed)
Cross. Table travel:(A) With 8" Knee (standard) 8" (203.2mm)(B) With 13" Knee . . 13" (330.2mm)
Vertical, knee travel:(A) Without coolant tank (standard) . . . . .15" (381mm)(B) With coolant tank. . . . . 11" (279.4mm\
Quill Travel:Distance, Spindle Nose (R-8) To Table Top:
(A) With plain overarm (standard) . . . . .t-314" (44.5mm) (minimum)(B) With compound overarm . . . .2-l/4" (57.2mm) (minimum)
Power-feed Options (feed rates) . Traverse speed 40IPM (16.93mm/SEC)Feed speed 3/4lPM (.3mm/SEC) to 25IPM (10.58mm/SEC)
Riser block option between column and turret .5" (127mm)Spindle to column face:
(A) With plain overarm (standard) . . . . . . 4" (l0Zmm) minimum,16-l/2" (419mm) maximum(B) with compound overarm 6-112" (165mm) minimum, 17" (43zmm) maximum
Range:Max. allowable size or weight of cutting tool and assembly. 1" end mill (25.4mm)Max. recommended weight of work piece and fixture. . . .375 Lbs. (170 Kg.)
(Refer to the American National Standard - Safety requirements for the construction, care, and use ofdrilling, milling and boring machine.)
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In order to become proficient in the use of a Millrite, the operator should first learn the locationand function of all controls. He should then operate each control, except the variable speed hand-wheel, with the power off in order to get the feel of how it operates. This is a general overall viewof the Millrite showing the location and names of the rnajor components and controls.
DRUM TYPEREVERSING SWITCH
CHART
SPINDLE LOCKMOTOR GUARD
HEAD LOCKING NUTS
NDLE BRAKE
oo*\
COLUI'rN--t/
TABLE FEED DIAL
TABLE FEED.- )HANDLE \-
TURRETT
QUILL LOCK
TURRET LOCKBOLT
SADDLE GIB LOCK
KNEE GIB LOCK
TABLE GIB LOC
KNEE GIB LOCK
QUILL FEEDHANDWHEEL
UILL FEED DIAL
DEFTH OFFEED SCALE
QUILL
COLLETS TRAY
TABLE
WERFEED UNIT(oPTroNAL)
CROSSFEEDDIAL
CROSSFEEDHANDWHEET
VERTICAL FEEDDIAL
VERTICAT FEEDHANDWHEEL
KNE
CRANE-I TON MIN.
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FIG 5LIFTING THE
MACHINE
TIGHTEN RAM LOCKINGBOLTS BEFORE LIFTING
PROPER LIFTINGSLING
TIGHTEN 4 BOLTSBEFORE LIFTING
MOVE TABLE AGAINSTCOLUMN
INSTALLED GROSSWEIGIIT OF MACI-.{INE
I 600LBS
UNCRATING: The Millrite is an accurate, precision built machine tool. It should be carefullv uncratedand inspected. Be sure that all items listed
-on the packing slip are contain.d i;1h; ;;;;;. iid;rr any
shortages immediately-. In the event of shopping d3rnage pliase hake a notation on rhe bill of lading, havethe delivering carrier sign to this effect, and notily powirmatic Burke.
STANDARD EQUIPMENT CARTON CONTAINS THE FOLLOWING ITEMS:1 - Draw Bar1 - Crank Handle
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lafeE requirements for the construction, care and use of Milling Machine.I - Installation and Maintenance Manuals1 - Operating Instructions ManualI - Warranty Card
Carefully read the Operating Instruction Manual before operating machine. Fill out the Warrantee cardand return to Powermatic Houdaille, Inc.
HANDLES: When crating, the two table handles are taped to table end brackets. The head finequill feedhandwheel is turned to face the machine. This handwheel should be reversed u"J tn. t"n-t. t uiaGr rr,o.rrabe assembled before operating.. Slide table handles and the head fine quill feed handwheel over the key,located in the head screw, table screw and cross travel screw. Tightei set screws located in the handlesand handwheel.
INSTALLATION OF MILL: The machine should remain on the skid until moved to its assigned workingarea. Position the head in its normal uprtght position. CAUTION - refer to article "pOSITIO1\|ING HEAD"before attemPting this maneuver. RoiatJ thi motor mounting bracket to the back of the machine. Tightenmotor mount bolt and the head locking nuts. Position the overarm as shown in figure 4 atrJ tilnt." ou..-arm locking lut!.Remove the four bolts-holding the machine ro the skid. Use
""r? i1 liftingtf,emactine
from the skid. If a overhead crane is used, be sule tha capacity is atleast 2000 pounds and lift the mill byplacing a sling lnder the ram as illustrated in.Fig. 4. Place thl machine on a sblid tevel floor, preferablyco.ncrete' in a dry well lighted area. When placing machine on a concrere foundation, it is advisJble to usea little grout (th-in mortar) to take care oT any unev€nness in the concrete as well as to proviJe a solidfoundation at all Points..When setting machini on a floor that has surface irregularitier, ,lii-, should beused to correct this condition to the greatest extent possible. NOTE: It is recommended that the machinebe lagged to the floor. See Fig. 5 for installation layoui.
LEVELING MACHINE ' Set machine by leveling the work table lengthwise and crosswise with a precisionlevel.
CLEANING: Thoroughly clean -protective. coating from machine with suitable cleaning solution.WARNING: It is not recommended that gasoline or atry other highly inflammable solvent be used. DO NOTmove the table, saddle,.knee or any moveable part until all wiyjhave been well cleaned and lubricated.(see lubrication page
. ) Then,-by-hand, moveiable, saddle "nd
krr.. to limit stop in one direction. Cleanand.lubricate expose,d ways and ihen move each unit to rhe opposite limit stop and similarly clean andlubricate the exposed ways. Loosen bolts to unlock the ram, und -ou. it forward and backward to the fulllength in order to clean and lubricate with SAE NO. 10 oil.
SAFEGUARDING THE HAZARD AREA
The safeguarding-of the" hazard area requires knowledge of the workpiece, its fixture or clamping method,the. operation to be performed, the cutter, if coolant iJto be used and in wirat form, the directionl q.rantityand velocity of the chips created and many other factors which determine the kind and nature oi t'he safe-guarding method which will best help to privent injuries.
The American National Standards Institute standard Bll.8-lg-74 section 5, a copy of which is supplied withthis mill, defines responsibiliq' for and the various methods of safeguarding'the htzard area. Review itsrecommendations and determine what method best fits the situati6n on io,r, operation and install itbefore using the mill for that operation.
If your comPany does not Possess the technical capibility to evaluate what is needed to protect and trainoperators' there are many capable firms available in most metropolitan areas to perform this service.
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CONNECTING PowER SUPPLY: To connect the machine to the plant power supply have a qualifiedelectrician proceed as followe:
1. 9*k required machine voltage and phase against power zupply to insure they are the same.2. Connect machine wiring to power supply mfing su.e conn"ction is in lompliance with local
electrical codes.3. Check for correct spindle rotation. (Forward position . . . . Counterclockwise)
LUBRICATION: Do not operate machine until properly lubricated. A number of Alemite fittings arelocated in different positions around the machin",-* .ho"* in Fig. 4. Using a greaEe gun filled with Sohiowaylube No. 50 or equivalent, lubricate the areas marked A. Uiing Sohio" fram XJ. 2 grease, lubricateareas marked B.
Lubricate the Timken bearings in the quill every 200 hours of operation. To accomplish this; First lowerthe quill until the ptlu^ q1$_is_expoeed. Then remove the pipe plug and pack the area with Sohio SactramNo. 2 or equivalent. DO NOT OVERFILL as this ttt"y
"",rr" eicessii heating in the spindle.
Specifically, the best greate to use for this purpose ie a ehot fibre, medium sponge grease, with sodiumsoap base. This is not- a critical requirement, however, the main concern is not to lubricate theee bearingstoo often or too heavily.
Lightly oil the top of the table and the outside surfaces of the quill with SAE No. l0 oil, not less thanonce a month while the machine is in use.
POSITIONING THE HEAD: The head is mounted in the swivel disc with four T-bolte and nute.l. (Standard) Model without worm/worm wheel drive: To reposition (swivel) the head, loosen three
nuts and crack loose the fourth nut only enough to allow the head to move when hand force isueed. Reposition (swivel) the head. Tighten the four nuts. CAUTION: NEVER loosen all fournuts.
2. Model with optional worm/worm wheel drive: To reposition (swivel) the head, loosen four nuts.Crank the shaft until the head reaches the position desiied. Ti[hien the four nuts.
REPOSITIONING (TILT) HEAD (ON MACHTNE WrTH OPTTONAL COMPOUND OVERARM): Thecompound swivel disc is locked to the overarm with two screwE on top.
l. (Standard) Model without worm/worm wheel drive: To reposition (tilt) the head, crack loose thetwo screws only enough to allow the head to move when hand force is used. RepoEition (tilt)the head. Tighten the two Ecrewr. CAUTION: NEVER loosen both screws.
2. Model with optional worm/worm wheel drive: To reposition (tilt) the head,loosen the two rcrewg.Crank the shaft until the head reaches the position desired. Tigirten the two Bcrew6.
ATIGNMENT oF HEAD: In 9as9 of precision boring or work of that nature, where it ie necessary tohave head perfectly Equare with the table, or when the position of the head has been changed, it is absol-utely neceesary to eweeP the table with an indicator to make sure the head is in a true
"eiical position.
Thie-is most easily accomplish"d by securing an indicator to the spindle nose to in a test bar held in thespindle.
NOTE: When indicating as in figures 7 and 8, it should be noted that the table is fitted to be slightlyhigh in front, approximately .0005".
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TO ADJUST PRETOAD OF TTMKENBEARINGS ON MITLRITE SPINDLE
Feed out quill until plug "A" is exposed.
Remove plug "A" with 5/16" Hex. key.
Rotate spindle manually until l/4" socket set ecrew"8" in preloading nut is accessible through plughole. Loosen this aet screw with UB" Hex. key.
Insert pin wrench in any of (3) 3/16" radial holesin preloading nut. Be careful not to damage threadin plug hole.
5. Turn spindle at "C" position to right to ir/creasepreload or vise Yersa.
Assure proper seating of bearing races on spindle - _by fightly tapping toiand bottoniof spindle. Rotate
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spindle to feel the "drag" on the bearinge. Thereshould be no noticable drag when running pre-dominatly at high spindle speeds.
Tighten eet ecrew "8" and replace outer plug "A"in quill. Make zure that plug clears quill housing,But do not force it in too far or it might interferewith inner rotating part8.
3.
4.
6.
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KNEE GIBS: To adjust the standard gtb o. the knee, back off the jam nuts on the seven gib adjustingscrews. Adjust the top and bottom screws in, until a light drag is felt when raising or lowering the knee.Lock their jam nuts. Now proceed with the second screw from the top and bottom and adjust in the sameas the first two screws. Then adjust the next two outside screws and finish up with the center and finalscrew. Be sure to relock all jam nuts as each screw is adjusted.
KNEE-TAPER GIB:A. Loosen bottom gib screw l/4 turn.B. Raise knee, by turning vertical screw, approximately one inch.C. Tighten top gib screw until tight.D. Move knee up and down. Continue steps A,B,C, and D until movement has proper feel.
SADDLE GIB: To adjust the standard saddle gib, back off all three set screws. Snug down the sockethead cap screw in the gtb to that a slight drag is felt when moving the saddle. Adjust the set screws inuntil they are tight. Check for free motion in both directions.
SADDLE_TAPER GIB:A. Position saddle away from the column (approximately to the end of the knee).B. Loosen the gib screw, to the rear of the saddle, l/4 turn.C. Tighten the front gib screw tight.D. Using cross feed screw move saddle away from and towards the column.E. Continue steps A,B,C, and D until movement has light drag feel.
TABLE GIB: To adjust the standard table gtb it will be necessary to remove the table, saddle assemblyfrom the knee. To accomplish this, it will be necessary to remove the saddle screw assembly. Remove thehandwheel, dial and then the screw support. By removing the three socket head cap scte*. holding it inthe saddle, rotate the screw until it is free from the saddle nut remove the screw assembly. Unlock the tableand saddle and then remove the saddle gb by removing the four socket head cap screws holding it in thesaddle. Lift the table and saddle assembly off the knee and set it on a bench or on the floor, table down.
Back off all set screws. Snug all cap Ecrews. Using the table handcrank check for a slight drag. Adjust theset screws in until they are tight. Check for free motion in both directions. Lightly oil the table and saddleways and reinstall on the knee. Mount the saddle gib and adjust it per preceeding instructions. Reinstallsaddle dial bracket and screw.
TABLE_TAPER GIB:A. Position table to the left hand side of the machine. This will aid getting to the one gib screw.B. Tighten the table gib adjusting screw, then turn table feed Ecrew.C. Repeat steps A and B until table movement has light drag feel.
GOOD HOUSEKEEPING: Good housekeeping is of major importance on preventative maintenance. Aclean machine will operate much longer, easier and more efficientally than a dirty one. Keep the millclean and free of chips, by using a chip rake or brush. DO NOT USE AIR to blow chops from OR USEHANDS to remove chips from the machine.
CONDITION OF ACCESSORIES: The condition of tool holders, tools, jig and fixtures, vised, dividingheads and other acceesoriee are important. Inspect these items on a regular basis. Keep them clean andcoated with a film of light oil to provent rust. Inspect the tapers and diamerers of all toolgand tool holders.Remove nicks and dents which would interfer with the proper seating of the taper. In insert type tools,index or replace damaged inserts.
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OYERALL CONDITION OF MACHINE: A periodic inspection and adjustment on a regular basis of notless than once every 6 months for:
A. Loose screwgB. Worn beltsC. Worn, damaged or missing partsD. Loose gibsE. Improperly operating adjusting Ecrews for the knee, saddle, table and quillF. Excessive lost motion in dialsG. Improper lubricationH. Loose electrical connectionsI. Column out of level and in twist
J. Bad bearingsAny problems discovered should be repaired as soon as poseible and if operator safety ir involved, themachine should be electrically locked out and red tagged until the repairs are made.
REPLACE BELT-STEP PULLEY: To replace a belt on a step pulley model, looeten the two wing nutson each side of the belt guard and swing the guard forward. Loosten the two l/2" hex nuts locking themotor bracket. Pull the motor bracket forward toward the front pulley. The belt is free to be removedfrom the machine and a replacement can be added. Swing the motor bracket back to teneion the beltand lock in position. Close the belt guard and lock it in position.
REPTACE BELT-VARIABLE SPEED: Lower the quill to its lowest point and lock in place. Remove thethree button head cap screws from either side of the belt guard with a l/8" Allen wrench. Using a Ecrewdriver remoye the four self tapping screws from the lower plate on the belt guard. At the front remove themolding and plate. Remove the speed adjusting cam by unscrewing the shoulder bolt in its center with a5116 Allen wrench. Lift the guard up and loosen and remove the four 51L6" socket head cap Bcrewsattaching the front plate to the lower plate and remoye the front plate. Take hold of one side of the beltand pull out to force the belt into its bottom position in the motor pulley. Drive out the pivot pin in theyoke arm and remove the yoke arm. Slip the belt out of the spindle pulley. Loosen and remove the fourLl2" hex head mounting screws holding the motor bracket to the lower plate. Tilt the motor, motorbracket and belt guard o[ to remoye the belt. Place a new belt in the motor p"U"y and pull out td bottomit in the pulley and retrace the previous steps.
V-BILT
MOTOR BRACKET
RPM PLATE
WING NUT
16
HEX NUT
REMOVING TABLE:l. Slide eyebolt and tee-slot key assenbly to the center of the table and tighten.2. Affix crane hook to the eve bolt.3. Position the table approximately I inchee to the right hand eide of the saddle center line. This
positions the table tcrew nut approximately to the center of the table screw.4. Remove the right hand table end bracket assembly.
A. Remove crank handle by loosening the set screw.B. Remove the Woodruff key in the table ecrew.C. Loosen thumb screw in the dial and elide dial off table Bcrew.D. Remove three eocket head cap screwr holding right table bracket to the table.
5. Remove the left hand table end bracket aseembly.A. Remove crank handle by loosening the set screw.B. Remove the Woodruff key in the table screw.C. L,oosen thumb Bcrew in the dial and elide the dial off the table Bcrew.D. Loosen bearing take-up nut and remove it and the outer thrust bearing.E. Remove three socket head cap rcrews holding the left table bracket to the table.F. With the crane ilpporting the table, slide the table from the saddle.G. When placing table on work bench, place clean candboard between dovetail and work
bench.H. Before reassembly, clean and lightly oil the table ways.
REMOVING SADDLE: It will be necessary to remove the table, saddle assembly.A. Remove the handwheel, dial and then the screw support by removing the three socket head
cap rcrews holding it in the saddle.Rotate the screw until it is free from the saddle nut.Remove the saddle screw aseemblv.Unlock the table and saddle and then remove the saddle gb by removing the four socket headcap Bcrews holding it to the saddle.Lift the table, saddle assembly off the knee and set it on a bench.If the table must be removed refer to table removal instructions.
REMOVING KNEE.A. l,oosen four nuts top of column and swivel turret, oyerarrn assembly approximately 90 Deg.B. Center the table to the saddle and lock in position.C. Poeition saddle towande the column, as close as possible, but be sure it clears the top of the
column and then lock.D. Loosen set screw, that holds the vertical feed nut.E. Position lifting sling around each end of the table.F. Gently lift table, saddle, and knee assembly from the column.G. If a desire exiets to remove the table, eaddle assembly, this ehould be done before steps A - G.
REPLACE SPINDLE WITHOUT REMOVING QUILT:l. Secure quill lock with quill in lowered position.2. Remove motor and draw bar.3. Take off spindle pulley, after loosening the set screw in the spindle pulley nut and unscrewing it.4. Mark the position of the pulley sleeve for re-assembly, unscrew 3 flat head ecrews that hold
it in place and take it off.5. Remove quill nut. Note: This nut has a left hand thread.6. Unecrew the pipe plug in the rear of the quill.7. Take off the snap ring on top of the spindle that holds it in position.B. Tap the spindle lightly and it will drop out.9. The new spindle is furnished with pre-adjusted and greased gearings so that to inetall it merely
reverse the above prosedure.CAUTIoN: Be sure that the snap ring is replaced with the correct side up.
B.C.D.
E.F.
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REMOVE MOTOR (STEP PULLEY): Loosen two wing nuts on each side of the guand and swing theguand forward. Loosen the two ll2" hex nuts that lock the motor housing to the motor head plate andslide the motor housing forward. Remove the "V" belt and the Il2" hex nuts. Disconnect the electricalwiring and fitting from the motor conduit box. Lift the motor, pulley and motor housing assembly from
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the motor plate. Remove the pulley retaining snap ring and loosen the set screw located in the pulley.Remove the housing and pulley by loosening the bolts in the motor adapter plate and sliding the pulley andhousing from the motor shaft. Remove motor adapter plate.
REMOVE MOTOR (VARIABLE SPEED): Lower the quill to its lowest point and lock in place. Removethe three button head cap screws from both sides of the belt guard with a l/8" Allen wrench. Using a screwdriver remove the four self tapping screws from the lower plate on the belt guard at the front. Remove themoulding and lower plate. Remove the speed adjusting cam by unscrewing the shoulder bolt in its centerwith a 5/16" Allen wrench. Lift the guard up and remoye the four 5/16" socket head cap screws attachingthe front plate to the lower plate and remoye the front plate. Take hold of one side of the belt and puiout to force the belt into its bottom position in the motor pulley. Drive out the pivot pin in the yoke armand remove the yoke arm. Slip the belt out of the spindle poll"y. it"tt ove the foui U2"-hexhead mountingscrews holding the motor bracket to the lower plate, tilt the motor, motor bracket and belt guand up toremove the belt. Remove the guard, then lift the motor, pulley and motor mounting bracket assemblyfrom the motor plate. Remove the retaining snap ring and slide pulley from the rnoto. shaft. Removemotor mounting bracket.
POWER FEBD INSTATTATION:Remove the handle, dial, key and end cap from the right hand end of the milling machil.Tap leadscrew U4-20 thread, 3/8 deep.Rework dial per Print 4-466Slide A-468 spacer and 4-470 bearing race on shaft.Move the table to the extreme left hand position in onder to have the leadscrew aE close to the rnut as possible.Screw the two 5/16-8 transfer screws into the outer holes that were used to support the originalright hand bearing bracket.Slide the Mill Table Feed with the C-680 or C-241 adaptor in place over the A-682 bearingrace and lightly tap the adaptor against the pointe of the transfer screwE marking the propeilocation for drilling.Remove the C-680 or C-241adaptor from the table feed and drill out two holes in the indicat-ed places to 2U64 Dia. Attach the adaptor to the mill using the 5/16-18 x l-3/4" socket capscrews supplied.Due to the variations in the length of the Millrite leadscrew, it may be necessary to shorten thespacer somewhat. The spacer and the bearing race should stick out about l-l/32- from the in-side surface of the adaptor casting. see drawing D-r64. Modify as required.
DRM UNIT INSTALTATION: Leave bearing raceusing the l/4-20 x l" socket head cap screws.
DIAL AND HANDCRANK INSTALLATION:
on leadscrew and place feed unit on the adaptor
l. After the bevel gear has been properly shimmed, the dial should be shimmed to provide .00S"spacing between the drive unit housing and the dial, Thie is important in onder io keep chipsout of the drive unit. Four washers are provided for this. (Two solid and two laminated)
2. Add A-780 sleeve and A-779 shaft exteneion. Secure with the screw provided.3. Slide collar to dial and secure.4. Add the key in the shaft extension. Install handle and secure.
18
LIMIT SWITCH INSTATTATION: (8" TABLE)l. Remove the two cap screws holding the existing "Tee" stop piece.2. Insert the two cylindrical standoffs into the counter bored holes in the "Tee" stop piece.3. Put the limit switch assembly over the two standoffs and screw dorrn the complete assembly
using the cap screws supplied.4. Replace the existing adjustable table stop pieces with the pair furnished.
Note: For proper operation of the limit switch assembly, the electrical stop should be engaged.4" before the mechanical stop is struck. This allows for coasting of the table when the feed ison the high speed setting. The table stop pieces should be turned until the proper spacing isprovided. in each direction.CAUTION: Do not allow the stop pieces to strike the body of the limit switch assembly.
5. The limit switch cable should be held off the ways using the cable clamp enclosed. Drill andtap B-32 into the table to secure the cable clamp.
LIMIT SWITCH INSTALTATION: (7" TABLE)l. Remove the adjustable stops and replace with A-465 table stop pieces as shovm on the Drawing
D-t64.2. Locate the limit switch assembly as shown, being sure to carefully center it over the stop in,
drill and tap 5/16-18 x l/2" deep into two places.3. Install limit switch assembly.
Note: For proper operation of the limit switch assembly, the electrical stop should be engaged.4" before the mechanical stop is struck. This allows for coasting of the table when the feed ison the high speed setting. Trim table stops to adjust, if required.CAUTION: Do not allow the stop pieces to strike the body of the limit switch assembly.
4. The limit switch cable should be held off the ways using the cable clamp enclosed. Drill and tapa B-32 hole into the table to secure the cable clamp.
CROSS TRAVEL POWERFEED :l. Remove handwheel dial and woodruff key from cross2. Rework dial to drawing A-466.3. Drill and ream leadscrew for shaft extension. Hole
feed leadscrew. Save kev and handwheel.
must be concentric to leadscrew o.d. towithin.00l T.I.R.
POWER UNIT INSTALLATION:l. Slip bearing race on leadscrew against thrust collar.2. Slide the adaptor and power feed unit against the bearing bracket. Spot the two 9/32 holes
(below the center line into the bearing bracket).3. Remove feed unit and bearing bracket. Tap U4 - 20 thread through two places.4. Return bearing bracket and feed unit to the mill and fasten using the two U4 - 20 x l-l/2 socket
head screws. (The screws may have to be shortened to clear the mounting boss for the bearingbracket.)
BEVEL GEAR INSTALTATION:l. Ineert shaft extension, then drill through leadscrew with l/8 diameter drill. Pueh in l/B x 5/B
roll pin - file ends smooth.2. See attached sheet. Note feed type number for correct instructions. Add AJ863 key.
19
KNEE POWERFEED vt. Remove dial collar dial, thurst collar and endcap.2. Secure internal thruet collar. A special set gcrew is provided for this. It will be necessary to drill
through the mill in line with the center of the thrust collar.A. Measure dimension on your mill and mark on outeide boss.B. Drill3/B Dia. through boss.C. Drill No. 29 (.136) through collar and approximately l/2" into leadecrew. Tap collar
8-32 thread.D. Install 4242 Bcrew.E. Replace endcap and external thruet collar.
3. Rework dial per print 4-1658.4. Slip bearing race on the gear shaft against the collar.5. Place feed unit over bearing race and against the boss. Spot the two holes through the unit using
a 9/32 Dia. drill. Remove unit and tap Il4-2O thread, l/2" deep. Also tap gear ll4-20 threadin shaft l/2" deep.
DRM UNIT INSTALTATION: Replace feed unit over the race against the mill and eecure with theIl4-20 x l-UA eocket cap screws.
BEVEL GEAR INSTALLATION: Note feed type number for correct instructions. Utilize the shaftextension to aid in shimming of gear. Leave the assembly in place and drill through pilot hole with No. 13(.183) drill. Ream drill 3/f6 Dia. Insert 3/16 x l-l/4 roll pin.
DIAL AND HANDCRANK INSTALTATION:l. Place a few ehims on the dial hub and slip on the dial. Remove shims until dial is spaced about v
.005" from the housing. Add collar.2. Add the spring, handcrank, washer and Tru-arc.
LIMIT SWITCH INSTALLATION: Limit switch on type 90 feed only. Refer to Drawing C-f94f
20
MILL POWER FEED OPERATION
GENERAL - Plug the feed into a source of 120 volt, 60 cycle, AC power having a current capacity of5 amperes.
CAUTION: All electrical apparatus should be properly grounded. The feed is provided with a 3 wire condthat includes a ground terminal. Do not cut this terminal off. On installations where the cord is wired to ajunction box be sure to ground the green wire. The feed direction is controlled by the main operatinghandle; handle to left, feed to left; handle to right, feed to right; handle in center, feed is stopped, com-pletely disengaged and the power is turned off. Feed rate is controlled by the black center knob. Feedrate is electronically regulated, which means that the feed will remain constant at any setting regardlessof load, within the capacity of the table feed.
RAPID TRAVERSE: A button is provided on the table feed which allowe the feed rate to be increasedto rapid without distrubing the selected feed rate. Do not hit the electrical stop in rapid traverse.
OVERLOAD PROTECTION: The circuit and motor are protected by a circuit breaker which will openwhen the feed is under excessive load. To reset, disengage feed, wait a few minutes, then push red buttonon the back side of the housing. DO NOT REPEATEDLY OVERLOAD THE FEED. If the circuit breakeropens, then the cutting load should be reduced before proceeding.
LIMIT SWITCHES: The limit switch is designed as a safety stop only and is not intended to be used asan accurate stop. The stopping point will be affected by the speed of the motor at the time the limit stopis struck. When the feed has shut itself off against a stop, the feed may be reversed and it will automatic-ally feed in the direction away from the stop without having to disengage the unit and crank away from theelectrical stop.
CAUTION: Do not hit stop in rapid traverse mode. Feed will coast into stop and may be damaged.
CAUTION: Do not allow this feed to drive into any positive stop as damage to the feed and the millingmachine may result. Always leave the stops eet to where they will at least prevent the feed from feedingagainst the end of the table travel.
CAUTION: Every attempt has been made to seal this feed. However, excessive amounts of coolants canwork their way in and ultimately damage the feed. For long life, keep the unit as dry as possible. Wipedown at the end of each day.
MOTOR BRUSHES: The motor is a commutator type with the brushes accessible from the outside. Thereplacement brush is available from your dealer or the factory. Please provide the serial number of yourfeed with your onder.
LUBRICATION: At assembly and every three months thereafter, greaEe the roller bearing and bevel gearwith bearing grease. Every three months of operation, remove the bottom coyer and grease the large spurgear. DO NOT OVER-GREASE THE SPUR GEAR. Damage to the motor may result. NOTE: The smallhole on the back of the feed near the top is a drain hole. Do not attempt to oil machine through this hole.Damage will result.
NOTE: Connect to ll0 volt, 50/60 cyele power only.
21
INSTRUCTIONS FOR INSTALLING RIGHT ANGLE ATTACHMENTl. Tighten the set screw located between the two holding cap screws to spread the casting for ease r
of assembly.2. Secure the attachment arbor on the spindle by means of the draw bar provided, but do not lock
it too tight. Once the taper is properly seated a snug fit will suffice.3. Loosen the center set screw.4. Secure the attachment in position by tightening the cap screws.
CAUTION: If the set screw is not released prior to securing the cap screws, the attachment willbe twisted and severely damaged.
ATIGNING THE ATTACHMENT AND OUTBOARD SUPPORTl. Insert the drive arbor in the attachrnent spindle, and re-position the outboard support until
the pilot of the arbor tits the bearing properly.2. Place an indicator in the maehine table with its pointer against the side of the arbor.3. Feed the table in and out, and re-position the turret of the machine until the arbor is at a true
90 Deg. angle to the in/out table movement.
PARTS ORDERSQuicker and better service will result when ordering repair parts if you will adhere to the followinginstructions. These seven requirements are essential:
l. Give complete serial number of machine.2. Give part name and number.3. State quantity wanted.4. Specify how and where to ship - Do not say "Ship the quickest way". Be definate and state
agency desired, that is - air mail, parcel post (special delivery), parcel post (regular), express,motor freight, rail freight, etc.
5. List each specific individual piece or assembly that is required in the order. If only certain partsof a unit are required, never use the wond "complete", it dways raises a question as to how muchof a unit to supply.
6. Parts must be ordered through Powermatic Burke Dealers.7. Give your Complete Address, zip code and telephone number.
TROUBLE SHOOTING
CHATTER
A. Incorrect Speed or Feed Consul t mi l l ing feed and speed tables for correct set t ing
B. Lack sf Rig id i ty in Set Up Reduce tool and/or qui l l overhangs, add addi t ional champingand/or back-up work piece. Reduce fued rate and depth of cut
C. Tool Loose in Holder Lock in holder or change to proper holder
D. Draw Bar Loose Tighten draw bar or check for damaged threads on draw bar orin holder. Check holder and spindle taper for f laws or d i r t . Replaceif reou ired
E. Unused Mot ions Not Locked Lock al l mot ions not used: qui l l , table, saddle, or knee
F. Loose Gibs Ad ius t a l l g i bs
G. Loose Overarm or Head Lock overarm to column and head to overarm
2. S P I N D L E R U N N O U T E X C E E D S S T D .
A. Spindle Bear ings Loose Adjust preload per maintenance manual
B. Bad or Incorrect Bear ings Replace bear ings
22
TROUBLE SHOOTING (cont'd. )
3 . S P I N D L E R U N S H O T
A. Excessive Preload Reduce preload to the set t ing indicated in the maintenancemanua l
B. Incorrect Lubr icat ion Check f o r ove r f i l l i ng w i t h g rease o r f o r no l ub r i ca t i on
C. Bad Bear ing Replace bear ing
4. E N D P L A Y I N S P I N D L E
No Preload Adjust preload to the set t ing indicated in the maintenancemanua l
B. Front Cao Loose T igh ten f r on t cap w i t h a spanne r w rench . l t shou ld l ock up onthe bear ings, not against the face of the qui l l
q E N D P L A Y I N O U I L L . A D J U S T M E N T '
A. Worn Nut or Screw (Fine Feed) Reolace nut and/or screw
B . Worn Gea rs (F i ne Feed ) Replace gears
C . Excess Back lash i n Gea rs (F i ne Feed ) Us ing a 5 /16 a l l en w rench l oos ten t he ' se t sc rew i n t he ad jus t i ngnut at the bot tom of the qui l l cover by hold ing the adjust ing nutwi th a spanner wrench, Adjust the nut using the spanner wrenchand then re- lock the set screw
D. Backlash Between Gear and Rack(Rap id Feed Ou i l l )
Adjust gear by unlocking set screw in cover and rotat ing eccentr icbush ing wh i l e ho ld i ng qu i l l handwhee l f r om ro ta t i ng
o , SL IDES LOOSE
A. Tab le G ib (S td . ) Loose Remove saddle handwheel , d ia l and screw. Remove table and saddleassembly and place on the f loor or table. Adjust g ib by back outt he se t sc rews (3 ) and t i gh ten ing t he cap sc rews (4 ) . Re ins ta l l t ab l esaddle and handwheel assemblv
B. Saddle Gib (Std.) Loose Adjust g ib by backing of f the set screws (3) and t ightening downthe cap screws (4) .
C. Knee Gib (Std.) Loose Un lock t he j am nu t s on t he (7 ) q i b ad jus t i ng se t sc rews on t helef t s ide of the knee. Star t ing wi th the top and bot tom set screwad ius t i n un t i l i t b i nds up t he knee and t hen back o f f un t i l t heknee moves f reely. Lock the iam nut . F in ish adjust ing the balanceof the screws in the same fashion. one at a t ime7 . END PLAY IN MOTION SCREWS
A. End Play in Table Screws Remove lef t end handcrank and dia l loosten set screw in threadedco l l a r . Ad jus t co l l a r t o m in im i ze end p l ay and l os t mo t i on i n d i a l
B. End Play in Saddle Screw Remove handwheel and dia l unlock set screw in threaded col larAd jus t co l l a r ' t d m in im i zeend p l ay and l os t mo t i on i n d i a l . Ad jus tspl i t saddle nut by t ightening the cap screw in the column sideo f t he nu t
C . End P lay i n Knee Ad jus tmen l Remove outs ide col lar and dia l . Unlock set screw in threadedco l l a r and ad jus t co l l a r t o m in im i ze end p l ay and l os t mo t i onin d i a l . l f Los t mo t i on i s s t i l l e xcess i ve sc rew and nu t wo rn andmay need to be replaced
8 . HEAD NOT SOUARE TO TABLE
A. Head not Square Lef t to Right Clamp an indicator in the spindle so. that i t can be used to t ramthe table zurface. Maximum error a l lowed is .001/ foot . Loostenthe thread of the four head cover ing screws. Back of f on the fourthbo l t bu t keep i t snug . Rea l l i gn head and re l ock t he f ou r moun t i ngscrews
B. Head not Square Front to Back (OnMach ines Equ iped w i t h CompoundOverarms)
Unclamp compound overarm by loosening the two cap screwon each s i de o f t he t r unn ion on l y enough t o a l l ow mo t i on w i t ha 3/8 a l len wrench. Rotate the head and check by t raming wi than i nd i ca to r moun ted on t he sp ind le . Max imum e r ro r a l l owed.001/foot
23
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