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Hardinge Bridgeport EZ Vision Installation, Maintenance, And Parts Manual Download Page 9

CHAPTER 5 - AUTOMATIC LUBRICATION SYSTEM

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Oil Viscosity Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Approved Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Lubricator Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Lubricator Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Adjusting the Oil Discharge Volume Per Cycle . . . . . . . . . . . . . . . . 5-3
Discharge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Lubricator Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Liquid Level Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Lubrication Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Uses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Specification Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

CHAPTER 6 - SAFETY GUARD INSTALLATION

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Machines with R-8 Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Machines with Erickson #30 or Universal #200 Quick-Change Spindle . . . . . . 6-3

Erickson #30 Quick-Change Spindle . . . . . . . . . . . . . . . . . . . . 6-3
Universal #200 Quick-Change Spindle . . . . . . . . . . . . . . . . . . . 6-3

Component Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

R-8 Safety Guard Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Quick-Change Safety Guard Assembly . . . . . . . . . . . . . . . . . . . . . 6-5

CHAPTER 7 - PARTS LISTINGS

Head Top Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Head Back Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Head Lower Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Basic Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Left End of X Axis Ballscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Right End of X Axis Ballscrew . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Ballscrew with Nut Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Y Axis Drive with Nutblock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
3rd Axis Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Operator Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Power Case, External View. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Power Case, Internal View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Power Case Terminal Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Operator Pendant and Power Case Component List . . . . . . . . . . . . . . . . 7-30

M-477A

vii

Summary of Contents for Bridgeport EZ Vision

Page 1: ...INSTALLATION MAINTENANCE AND PARTS LIST EZ Vision Automated Milling Machines Revised March 28 2008 Manual No M 477A Litho in U S A Part No M A 0009500 0477 May 2007 TP7441 ...

Page 2: ...nformation in this manual Reproduction of this manual in whole or in part without written permission of Hardinge Inc is prohibited CONVENTIONS USED IN THIS MANUAL WARNINGS Warnings must be followed carefully to avoid the possibility of personal in jury or damage to the machine tooling or workpiece CAUTIONS Cautions must be followed carefully to avoid the possibility of damage to the machine toolin...

Page 3: ...and machine tool operators be advised of the importance of safe maintenance setup and operation of Hardinge built equipment Our recommendations are described below BE SURE TO READ THESE SAFETY RECOMMENDATIONS BEFORE PROCEEDING ANY FURTHER READ THE APPROPRIATE MANUAL AND OR INSTRUCTIONS before attempting opera tion or maintenance of the machine Make certain that you understand all instructions DON ...

Page 4: ...unted and secured before starting the machine MAKE CERTAIN all tools are securely clamped in position before starting the machine REMOVE ANY LOOSE PARTS OR TOOLS left on machine or in the work area before op erating the machine Always check the machine and work area for loose tools and parts especially after work has been completed by maintenance personnel REMOVE CHUCK WRENCHES before starting the...

Page 5: ...ishes or dimensions of workpiece near running spindle or moving slides DON T JOG SPINDLE in either direction when checking thread with a thread gage DON T ATTEMPT to brake or slow the machine with hands or any makeshift device ANY ATTACHMENT TOOL OR MACHINE MODIFICATION not obtained from Hardinge Inc must be reviewed by a qualified safety engineer before installation USE CAUTION around exposed mec...

Page 6: ...ce awareness barrier awareness device or shield To assist machine users in designing point of operation safeguarding for their specific machine applications the Occupational Safety and Health Administration has published a booklet entitled Concepts and Techniques of Machine Safeguarding O S H A Publication Number 3067 This publication is available from The Publication Office O S H A U S Department...

Page 7: ... Side View 1 6 Head Specifications 1 7 Head Dimensions 1 8 Spindle Specifications 1 9 CHAPTER 2 INSTALLATION Uncrating 2 1 Shortages 2 1 Cleaning and Lubricating 2 1 Machine Floor Plan 2 2 Lifting the Machine 2 3 Placing Machine on a Solid Foundation 2 4 Control Pendant Installation 2 6 Power Case Inspection 2 8 Connect the Electrical Power 2 9 Protective Ground 2 10 Prestart Checks 2 11 Start Up ...

Page 8: ...ers 3 5 Clean the Interior of the Power Case 3 5 Semi Annually 3 6 Check the Pneumatic Regulator System Bowl 3 6 Drain and Clean the Pneumatic Filter Bowls 3 6 Check the Spindle Motor for Dirt 3 6 Check the Spindle Drive Belt for Dirt and Wear 3 7 Grease the Vari Drive 3 7 As Specified on Lubrication Tag 3 7 As Required 3 7 CHAPTER 4 MAINTENANCE Spindle Drive Motor Removal 4 1 Drive Belt Replaceme...

Page 9: ... Machines with R 8 Spindle 6 2 Machines with Erickson 30 or Universal 200 Quick Change Spindle 6 3 Erickson 30 Quick Change Spindle 6 3 Universal 200 Quick Change Spindle 6 3 Component Lists 6 4 R 8 Safety Guard Assembly 6 4 Quick Change Safety Guard Assembly 6 5 CHAPTER 7 PARTS LISTINGS Head Top Housing 7 1 Head Back Gear 7 4 Head Lower Housing 7 8 Basic Machine 7 14 Left End of X Axis Ballscrew ...

Page 10: ... NOTES viii M 477A ...

Page 11: ... M 477A 1 1 Figure 1 1 3 Axis Milling Machine TP6891 Control Unit Ram Z Axis Ball Screw Housing 3 Axis Machines Only Turret Electrical Control Box Keypad Table X Axis Handwheel Y Axis Handwheel Knee Knee Crank Handle Removed Column Base Quill Spindle ...

Page 12: ...iform load 300 lbs 136 kg T slots 3 2 5 in Cntr 64 mm T slot size 625 in 16 mm SPACE AND WEIGHT Floor area door open 8 2 x 7 3 ft 2 5 x 2 2 m Floor area door closed 8 2 x 5 3 ft 2 5 x 1 6 m Height 6 8 ft 2 1 m Net weight 2340 lbs 1061 kg Shipping weight 2900 lbs 1315 kg SPINDLE AC spindle motor rating continuous 2 hp 1 5 kw Power rating 3 hp 2 2 kw Duty cycle 30 min duty rated Spindle speed Hi 500...

Page 13: ... 2 axis linear or 2 axis circular interpolation 10 5 inch color conversational display Absolute and incremental programming Automatic corner rounding Mathematical help modes Powerful canned cycles for machining arcs diagonals circles bolt hole patterns pocket milling and more Cutter diameter compensation English metric conversion 1000 block program storage Disk storage standard 3 5 in diskette HD ...

Page 14: ... 48 in 1219 mm Dimension A B C D E F Minimum 82 2083 51 1295 8 75 222 2 5 64 0 6 75 171 Maximum 84 2140 63 1600 20 75 527 18 25 470 12 305 18 75 476 All dimensions shown in inches millimeters 1 4 M 477A Figure 1 2 Principal Dimensions TP5660A 5 Inch Quill Travel ...

Page 15: ...MACHINE DIMENSIONS FRONT VIEW M 477A 1 5 Figure 1 3 Machine Dimensions Front View 46 Back Splash TP5662A 48 Optional Coolant Tank 97 Table at X Travel Limit 67 ...

Page 16: ...SIDE VIEW 1 6 M 477A Figure 1 4 Machine Dimensions Side View TP5661A 84 with Power Draw Bar 82 without Power Draw Bar 47 4 Maximum 31 4 Minimum 13 0 Maximum 1 0 Minimum ...

Page 17: ... mm dia Drilling Capacity Power 0 37 in 9 4 mm dia Boring Capacity 6 75 in 152 4 mm dia Milling Capacity 2 0 cu In min 32 cc min Spindle to Column Minimum 6 75 in 171 mm Maximum 18 75 in 476 mm RECOMMENDATIONS 1 Use 2 3 or 4 flute end mills Eight flute end mills are usually not satisfactory for general milling When using shell mills face mills or any other tooling proper machining practice should ...

Page 18: ...HEAD DIMENSIONS 1 8 M 477A Figure 1 5 Head Dimensions TP5663 ...

Page 19: ...0 4200 Motor 2 HP 1 5 kw Quill travel 5 in 127 mm Power feed of Quill 0 0015 in 0 04 mm per rev of Spindle 3 rates 0 003 in 0 08 mm 0 006 in 0 15 mm Collet capacity 1 8 in x 1 16 in 3 9 mm x 1 5 mm Weight 196 lb 89 kg 2 HP Continuous 3 HP Intermittent M 477A 1 9 ...

Page 20: ... NOTES 1 10 M 477A ...

Page 21: ...G AND LUBRICATING WARNING DO NOT use gasoline or any other flammable cleaning agent for cleaning ma chine CAUTION DO NOT attempt to operate the machine until all ways have been well cleaned and lubricated 1 Thoroughly clean the protective coating from machine with a suitable cleaning solution 2 Move the table saddle and knee by hand to a limit stop in one direction 3 Clean and lubricate the expose...

Page 22: ...nts 2 2 M 477A Figure 2 2 Machine Floor Plan Top View TP5669 8 5 216 NOTE All dimensions shown in inches millimeters 85 2159 28 5 724 34 864 35 25 895 22 75 578 62 1575 Removable Coolant Pan Option 21 534 20 508 Electrical Power Input 1 3 8 Diameter for 1 Conduit Fitting Coolant Reservoir Open for Inspection ...

Page 23: ...re lifting with a sling The machine should be lifted by placing a sling under the ram as shown in Figure 2 3 Be sure to use the proper sling when lifting the machine M 477A 2 3 Figure 2 3 Proper Method of Lifting the Machine TP5668 Tighten four bolts to 47 lb ft 64 Nm before lifting the machine Tighten ram locking bolts before lifting the machine Use the proper strap Move the saddle forward or bac...

Page 24: ...tting machine on a floor that has any surface irregularities use shims to correct this condition to the greatest extent possible Refer to Figure 2 4 3 Level the machine by checking the work table lengthwise and crosswise with a precision instrument as shown in Figure 2 5 4 Verify that all four corners are making contact with the floor after the machine is leveled If all four corners are not making...

Page 25: ...bolts used to secure the machine to the skid during shipment can be used to secure the machine to the floor 5 Install and tighten the hold down bolts to secure machine to floor Refer to Figure 2 6 6 Recheck the machine for level Adjust as needed M 477A 2 5 Figure 2 6 Hold Down Bolt Machine Dimension TP5383 5 75 146 mm 625 DIA ...

Page 26: ...rol pendant 3 Slide upper mounting bracket D over the end of rod E 4 Install the lower mounting bracket as shown in Figure 2 7 5 Connect cable F to the back of the control pendant 6 Route wire carrier G Figure 2 8 to the bottom of the power case 7 Secure the cable and wire carrier to the pendant arm with straps H 2 6 M 477A Figure 2 7 Pendant Mounted on Arm TP7443 D E C F Figure 2 8 Pendant Arm TP...

Page 27: ...power case 12 Connect the wire carrier to the bottom of the power case 13 Remove wireway cover L 14 Route the fiber optic cable to the motion control unit and connect as shown in Figure 2 11 15 Install wireway cover L Figure 2 10 16 Tighten cord grip K Leave the power case door open for additional procedures M 477A 2 7 Figure 2 9 Power Case Door I J J TP6893A Figure 2 10 Internal View of Power Cas...

Page 28: ...Amps Voltage Full Load Amps 200 V 6 5 200 V 6 2 220 V 6 6 208 V 6 1 380 V 3 3 220 V 5 8 415 V 3 2 230 V 5 8 440 V 3 3 460 V 2 9 B Locate the appropriate Full Load Amp value for the machine based on the frequency and voltage of the electrical service to be used C Multiply the Full Load Amp value by 1 1 The result will be a realistic setting for the spindle overload D Check the adjustable dial on sp...

Page 29: ...le with the machine voltage which is stamped on a plate mounted on the outside of the power case door 2 Turn OFF the power source to be connected to the machine 3 Verify the incoming power is properly grounded NOTE Use a cable clamp to secure the cable at the entrance to the power case 4 Route the power cable into the top of the power case far enough to easily reach the top of disconnect switch N ...

Page 30: ...ically 3 ohms COPPER STAKE IN DIA 6 8 FT LG When properly driven into the ground below permanent moisture level the impedance of this type is typically below 5 ohms FOURTH WIRE GROUND Although a copper ground stake is preferred an alternative is a fourth wire for ground included with the power wires from the enclosure ground stud to the power company service panel ground bus See Note below OTHER M...

Page 31: ...ubricator shown in Figure 2 1 Refill the oil reservoir if necessary Refer to Chapter 5 for additional information on the automatic lubrication system 6 The air pressure level must be adjusted to nominal 80 psi 5 5 bar This air pressure requirement is applicable only if the power drawbar is installed 7 The machine way areas are cleared cleaned and lubricated CAUTION DO NOT use coolant containing th...

Page 32: ...NEUTRAL LO lever when the spindle is motion 2 Check spindle rotation A Set Spindle Direction switch P Figure 2 14 to FORWARD B Set HI NEUTRAL LO lever Q Figure 2 15 to HI 3 Check spindle rotation The spindle should rotate clockwise when viewed from the top of the machine 4 Verify the door fan is blowing air into the power case 2 12 M 477A Figure 2 14 Operator Control Panel P TP7442 Figure 2 15 Mac...

Page 33: ...Sweep the indicator around the spindle centerline to check the Y axis tram as shown in Figures 2 18 and 2 19 If the axes are within specification not adjustment is required If the axes are not within specification leave the indicator in the spindle and use the appropriate procedure to adjust tram M 477A 2 13 Figure 2 16 X Tram Check Indicator to the Left TP6977 Figure 2 17 X Tram Check Indicator t...

Page 34: ...21 to adjust the X axis tram as needed 5 Tighten the four locknuts in the sequence shown in Figure 2 22 A Torque to 25 lb ft 33 9 N m B Torque to 50 lb ft 67 8 N m 6 Sweep the indicator around the spindle centerline to verify the adjustment 7 Remove the indicator from the spindle if tram adjustments are complete 2 14 M 477A Figure 2 20 Positioning the Head Front View TP5372 R Figure 2 21 Positioni...

Page 35: ...out with the specification on page 2 13 4 Use vertical adjustment worm shaft U Figure 2 23 to adjust the Y axis tram as needed 5 Tighten the three ram locking bolts to 75 lb ft 102 N m 6 Sweep the indicator around the spindle centerline to verify the adjustment 7 Remove the indicator from the spindle if tram adjustments are complete M 477A 2 15 Figure 2 23 Head Tilt Bolts T U TP5375 ...

Page 36: ... NOTES 2 16 M 477A ...

Page 37: ...omatic lubrication system Clean dirt and chips from ways WEEKLY Clean way covers and lightly oil Check coolant level Check flood coolant Apply oil to drawbar Apply oil to spindle MONTHLY Clean machine exterior Clear air intakes and exhausts Check air filters Replace if necessary Use electrostatic filters if dry cutting SEMI ANNUALLY Check pneumatic lubricator bowl Fill if necessary Drain clean and...

Page 38: ...achine manufacturer and must be provided by the machine owner Use an industrial vacuum cleaner and clean the exterior of the machine frequently Do not use compressed air to clean the machines Use specially designed vacuum systems at the cutting tool Use electrostatic filters if clean air cannot be directed to the head or the control cabinet inlets EQUIPMENT AND SUPPLIES The following items will be...

Page 39: ...terial into the inter locking parts control system or at the operator resulting in machine dam age or personal injury Clear dirt and chips from the ways at the end of the day Use a brush and or an industrial wet or dry vacuum cleaner then wipe carefully to remove damage causing abrasive mate rial WEEKLY Clean the Way Covers and Lightly Oil Clean and apply a light coat of oil to the way covers to k...

Page 40: ...to the top of the drawbar Refer to the lubrication plate on the right side of the machine head Apply Oil to the Spindle Add five drops of Mobil DTE Light oil to spindle oil cup B Figure 3 1 Refer to the lubrication plate on the right side of the machine head 3 4 M 477A Figure 3 1 Oil Cups on the Machine Head A B TP6979 ...

Page 41: ... placed The time between filter changes cannot be predicted because it depends on many things including the hours of operation per day and the nature of materials being machined in the vicinity Clean the air filters Replace the air filters when you can no longer see light through them Dirty shop air can cause damage to the control system if not filtered properly Clean the Interior of the Power Cas...

Page 42: ...m water to clean the filter bowls Using soap solvent or chemicals may weaken the bowl and cause it to burst resulting in serious personal injury To drain and clean the bowls 1 Put a dry rag under the regulator to catch the drips 2 Drain the filter bowls by pressing up on the drain valves 3 Turn the air supply to the machine OFF 4 Gently unscrew both bowls 5 Rinse the filter bowls with WARM WATER o...

Page 43: ...emove screw C Figure 3 2 from the Vari Drive grease port 2 Introduce 08 fluid ounces 2 5 milliliters of Lubriplate No 107 grease into the Vari Drive grease port 3 Replace screw C AS SPECIFIED ON LUBRICATION TAG OIL THE QUILL DOWNFEED TWICE WEEKLY Add five drops of Mobil Vactra Oil No 4 to downfeed oil cup A Figure 3 1 Refer to the lubrication plate on the right side of the machine head AS REQUIRED...

Page 44: ... NOTES 3 8 M 477A ...

Page 45: ...to the highest speed 6 Remove the reversing switch from the belt housing 7 Remove two securing screws D 8 Pull back on the motor then push the motor forward 9 Reach up inside and pull the drive belt back 10 Lift the motor and rest the case on stud E Figure 4 2 11 Ease the belt over the lower drive disc and remove the motor M 477A 4 1 Figure 4 1 Motor Removal Front View A C B D TP5320 Figure 4 2 Mo...

Page 46: ...hem into the adjacent tapped holes and withdraw bearing housing G 3 Remove the two screws and bushings H 4 Remove four screws I and one screw J 5 Remove the four screws securing speed changer K 6 Remove top housing L Tap to clear the dowels 7 Replace the belt 4 2 M 477A Figure 4 3 Drive Belt Replacement TP5322 F G I K L J H ...

Page 47: ... the quill to full extent 3 Remove two lower cap screws M Figure 4 4 from the speed changer housing 4 Remove four cap screws N 5 Remove top assembly O and tap to clear dowels 6 Replace the belt M 477A 4 3 Figure 4 4 Timing Belt Replacement TP5323 M O N ...

Page 48: ...emove two screws P Figure 4 5 3 Remove clutch hub assembly Q 4 Replace brake shoes R 5 Remove the bearing drive discs and circlips from hub assembly Q 6 Replace the bearing and housing S 7 Thread the hub through the bearing and reassemble the discs Replace top housing and motor 4 4 M 477A Figure 4 5 Brake Shoe Replacement S Q R P TP5324 ...

Page 49: ...3 Remove retaining ring C screw D and arm E 4 Thread shaft F through the micro nuts and remove 5 Remove screw G and stop H 6 Remove the quill 7 Clean all areas oil liberally and reassemble 8 Check correct operation of micro feed trip assembly together with feed trip linkage as per the Feed Trip Adjustment on page 4 7 M 477A 4 5 Figure 4 6 Micro Feed Trip Assembly and Quill Removal B A H G F C E D ...

Page 50: ...asing spring tension 4 Lift the end of the spring from the pin on the pinion shaft 5 Rotate housing M counterclockwise from the head casting 6 Remove the spring from the housing and replace 7 Refit the spring to the main housing casting Turn the housing clockwise until the spring locates on the pin in the pinion shaft 4 6 M 477A Figure 4 7 Balance Spring Replacement I TP5326 J K L M 1 1 2 Turns ...

Page 51: ...the micro nuts against quill stop O NOTE The machine will not be able to drill if adjusting screw Q is set too light 4 Slowly turn adjusting screw Q until lever P trips 5 Secure locknut N 6 Check for quick action response M 477A 4 7 Figure 4 8 Feed Trip Adjustment O P N Q TP5327 Engage ...

Page 52: ...ock screw T and collet aligning screw U 5 Replace collet aligning screw U 6 Insert a collet and check that the dog on the end of the screw does not interfere with the bottom of the guide slot 7 Replace lock screw T 8 Replace nose cap S Check felt pen markings for correct alignment 9 Replace set screw R CAUTION DO NOT over tighten as this will cause distortion 10 Verify gap V is 0 003 in 0 08 mm 4 ...

Page 53: ...Figure 4 11 2 Mount two magnetic based indicators on the front angular face of the saddle 3 Push the right end of the table by applying 50 lbf 222 N and pull the left end of the table by applying 50 lbf 222 N as shown in Figure 4 11 4 Zero the indicators M 477A 4 9 Figure 4 10 Left Indicator Position for Table Gib Adjustment TP6995 Figure 4 11 Indicator Positions for Table Gib Adjustment TP6998 Di...

Page 54: ...10 mm A Adjust the gib by tightening gib screw A Figure 4 12 slightly until a slight drag is felt when moving the table by hand B Repeat steps 3 through 6 to check the gib adjustment Repeat as needed 8 Remove the indicators from the machine 4 10 M 477A Figure 4 12 Table Gib Adjustment Screw TP6993 A Indicator Readings Values Inch Millimeter Minimum Indicator Readings 0002 005 Maximum Indicator Rea...

Page 55: ...ner Refer also to Figure 4 15 3 Clean the dovetail surfaces to be used to mount the magnetic based indicators 4 Mount two magnetic based indicators on the left dovetail surface on the top of the knee 5 Push the right end of the table by applying 50 lbf 222 N and pull the left end of the table by applying 50 lbf 222 N as shown in Figure 4 15 6 Zero the indicators 7 Pull the right end of the table b...

Page 56: ...moving the saddle by hand B Repeat steps 5 through 8 to check the gib adjustment Repeat as needed 10 Remove the indicators from the machine 11 Install front saddle wiper B Figure 4 13 and secure with three screws 4 12 M 477A Figure 4 15 Indicator Positions for Saddle Gib Adjustment TP6999 Direction of Force Applied to the Table Front Indicator Table Saddle Rear Indicator Figure 4 16 Saddle Gib Adj...

Page 57: ... Figure 4 19 4 Use a hex wrench to loosen the gib adjustment screws approximately turn 5 Alternately and evenly torque the gib adjustment screws to 40 lb in 4 5 N m NOTE DO NOT allow the gib adjustment screws to turn while tightening the jam nuts 6 Hold the gib adjustment screws in place with the hex wrench while tightening the jam nuts M 477A 4 13 Figure 4 17 Rear View of the Saddle TP7000 D Figu...

Page 58: ... NOTES 4 14 M 477A ...

Page 59: ... fed from a central lubricating reservoir which contains a filter and motorized timed plunger pump The lubricator is located on the left side of the machine column Refer to Figure 5 1 OIL VISCOSITY RANGE The viscosity range is 150 to 8000 SUS at operating temperature APPROVED LUBRICANTS The following lubricants or equivalents are approved for use in the automatic lubrication system Gulf Oil Corp G...

Page 60: ...oo little oil check the following and repair as necessary Low oil level Broken or cracked tubing Loose connections Flattened lubricator outlet tube Clogged filter MOTOR REPLACEMENT NOTE During reassembly ensure the slot in the motor shaft is engaged with the pin in the drive shaft before replacing the screens Remove the motor cover and the two screens holding the motor to the top of the reservoir ...

Page 61: ...aduations ranging from 1 to 5 The number indicates the approximate discharge volume in cubic centimeters 1 Lift collar A to allow Manual Feed knob B Figure 5 2 to be rotated 2 Rotate the Manual Feed knob as follows Clockwise to decrease the discharge volume Counterclockwise to increase the discharge volume 3 Release collar A Discharge Pressure The discharge pressure is 60 PSI maximum Peak system p...

Page 62: ...equired Remove the filter as follows Slide the spring clip OFF Remove the filter disc and spring LIQUID LEVEL SENSOR The oil reservoir is equipped with an oil level sensor The following conditions exist if the lubrication oil level falls below the minimum level Automatic machine operation is inhibited Manual spindle operation is inhibited Add lubrication oil to the Maximum mark on the reservoir 5 ...

Page 63: ...hine LUBRICATION SPECIFICATIONS WAYLUBE ASTM OR ABLE LUBE NUMBER 315 VISCOSITY S U S 100 F 283 347 210 F V I MINIMUM FLASH POINT F MINIMUM 350 POUR POINT F MAXIMUM 0 MAXIMUM OP TEMPERATURE F 150 ADDITIVES OR INHIBITORS R F S TEST REQUIREMENTS TIMKIN O K LD MINIMUM OXIDATION ASTM D 943 MINIMUM HOURS NEUTRAL NUMBER CHG ASTM D 943 MODIFIED CU CORROSION ASTM D 130 STAIN ABLE ACCELERATED BREAKDOWN TEST...

Page 64: ... NOTES 5 6 M 477A ...

Page 65: ...ds will be suitable for some operations but not for others Carefully analyze the operation to be performed before deciding whether this safeguard is suitable Adjust the safeguard to suit your special requirements If you find that it is not suitable for a particular application you should use an alternate form of protection WARNING Some coolants and cutting oils contain chemicals harmful to the saf...

Page 66: ...nch 1 Place mounting ring B underneath top of guard D Figure 6 1 2 Place two socket head cap screws A through the holes in ring and hand start them into the threaded holes in the nose cap until hand tight 3 Align guard to be square with the table of the machine unless angular mounting is desired 4 Tighten screws with a 3 16 Allen wrench 6 2 M 477A Figure 6 1 Safety Guard for Machines with an R 8 S...

Page 67: ...by turning it counterclockwise 2 Place the nose cap mounting ring O up against the quill nose cap and install the four button head cap screws M Figure 6 2 NOTE The counterbored side of the nose cap mounting ring fits against the nose cap 3 Lower the quill Place the clamping ring P underneath the top of the guard Q and position the guard under the spindle 4 Install the four socket head cap screws N...

Page 68: ...191201 Ring Guard 1 C BP 11191204 Shield Left Side 1 D BP 11191206 Shield Assy Top 1 E BP 11665810 Screw Button Hd Cap 10 32x 750 3 F BP 11010065 Washer Plastic 10 32 8 G BP 11010055 Nut Stop Plastic 10 32 3 H BP 11010063 Screw Drive Type U 12 x 625 2 I BP 11191205 Shield Right Side 1 J BP 11191203 Assembly Rear Shield 1 K BP 11121202 Assembly Front Shield 1 L BP 11010056 Screw Hand 10 32 x 750 4 ...

Page 69: ...10 32x 750 3 F BP 11010065 Washer Plastic 10 32 8 G BP 11010055 Nut Stop Plastic 10 32 3 H BP 11010063 Screw Drive Type U 12 x 625 2 I BP 11191205 Shield Right Side 1 J BP 11191203 Assembly Rear Shield 1 K BP 11121202 Assembly Front Shield 1 L BP 11010056 Screw Hand 10 32 x 750 4 M BP 11651199 Screw Button Hd Cap 10 32 x 500 4 N BP 11980224 Screw Socket Hd Cap 8 32 x 625 4 O BP 12190330 Ring Guard...

Page 70: ... NOTES 6 6 M 477A ...

Page 71: ...CHAPTER 7 PARTS LISTINGS HEAD TOP HOUSING M 477A 7 1 TP5340 ...

Page 72: ...t Hd Cap 10 32 x 2 18 BP 11180095 Washer 1 19 BP 12180089 Sleeve Pivot 2 20 BP 12180093 Washer Drawbar 1 21 BP 11180915 O Ring Parker 2 14 1 22 BP 12180056 Housing Spindle Pulley Bearing Sliding 1 23 BP 11170262 Bearing Ball Fafnir RM9110NPP 1 24 BP 11182124 Insert Plastic 2 25 BP 12183934 Varidisc Adjustable Drive A 1 26 BP 11180855 Ring Retaining 5102 156 1 27 BP 11182120 Belt Varispeed 1 28 BP ...

Page 73: ...Screw Drive Type U 0 x 8 58 BP 11182893 Nameplate Hi Low Range 1 61 BP 11182894 Nameplate Quill Feed 1 63 BP 12180053 Housing Gear 1 64 BP 11011443 Screw Round Hd Machine 10 24 x 3 8 3 65 BP 11185030 Plate Gear Housing 1 66 BP 11180818 Ring Snap 5100 25 1 67 BP 11182306 Finger Brake Operating 2 68 BP 12180083 Stud Brake Finger Pivot 1 69 BP 11192151 Knob Bakelite x 20 1 70 BP 12190133 Handle Brake...

Page 74: ...HEAD BACK GEAR 7 4 M 477A TP5341 ...

Page 75: ...d Change 1 18 BP 11181233 Screw Socket Hd Set 1 4 UNC x 3 8 1 19 BP 11182178 Handle Machine 3302 1 20 BP 11182892 Plate Caution 1 24 BP 11011287 Screw Stainless Steel 20 x 2 25 BP 11011037 Screw Socket Hd Cap 20 x 1 1 4 4 27 BP 11183645 Bushing Oilite 1 28 BP 28300619 Pin Roll 2 5mm x 12mm Lg 1 29 BP 28025716 Shaft Speed Changer 1 30 BP 28007307 Gear Boston Worm 1 31 BP 11180214 Bushing Oilite Fla...

Page 76: ...asher Wave Spring 1 59 BP 12180067 Bull Gear Shift Pinion 1 60 BP 12180161 Plate Hi Low Detent 1 61 BP 11181732 Nut Hex 3 8 16 3 62 BP 11151913 Lockwasher 3 8 3 63 BP 12180085 Studs 3 66 BP 12180100 Plunger Hi Low Detent 1 67 BP 11182072 Spring x 0 032 x 9 16 1 68 BP 11011017 Screw Socket Hd Cap 10 32 x Lg 2 69 BP 11192151 Knob Bakelite 20 1 70 BP 12180099 Crank Hi Low Shift 1 71 BP 12180096 Block...

Page 77: ...5 8 Lg 2 86 BP 12550016 Pulley Timing Belt 1 87 BP 11191738 Nut Hex Jam 5 8 18 1 88 BP 11182912 Nameplate Speed Change 1 89 BP 11011139 Screw Flat Hd Machine 8 32 x 0 750 2 90 BP 11182897 Plate Lubrication 1 93 BP 11182655 Drum Switch 1 Items 37 and 38 sold as assembly only Items 40 and 83 sold as assembly only M 477A 7 7 ...

Page 78: ...HEAD LOWER HOUSING 7 8 M 477A TP5343 ...

Page 79: ...190168 Pin Feed Engage 1 17 BP 12190059 Cradle Word Gear 1 18 BP 12190169 Throw out Worm Gear Cradle 1 19 BP 12190170 Sleeve Shift 1 20 BP 12190138 Pin Shift 2 21 BP 11192052 Spring Compression 2 22 BP 11010517 Pin Roll 1 8 x 2 23 BP 12190064 Crank Shift Crank 2 24 BP 11192151 Ball Black Plastic 1 Dia 4 25 BP 11011010 Screw Socket Hd Cap 10 24 x Lg 7 26 BP 11011258 Setscrew 10 24 x 3 8 1 27 BP 121...

Page 80: ...156 1 54 BP 11011375 Setscrew Dog Point 0 312 18 x 0 250 1 55 BP 12190157 Rod Reverse Clutch 1 56 BP 11010509 Pin Roll 3 32 x Lg 1 57 BP 12190198 Shaft Feed Worm 1 58 BP 12190200 Pin 3 32 x 5 16 Lg 1 59 BP 28007308 Pin 0 110 x 7 16 Lg 1 60 BP 12190179 Rod Feed Shift 1 61 BP 11011260 Setscrew 10 32 x Lg 1 63 BP 11190061 Fork Feed Gear Shift 1 64 BP 12193446 Assembly Cluster Gear Shift Crank 1 66 BP...

Page 81: ...od Cam 1 104 BP 12190095 Handle Trip 1 106 BP 12190067 Bracket Feed Trip 1 107 BP 11011035 Screw Socket Hd Cap 20 x 1 Lg 2 111 BP 12193433 Assembly Reverse Knob 1 113 BP 12190159 Assembly Handwheel Clutch 1 116 BP 12190154 Screw Handwheel Clutch Spring 1 117 BP 11010515 Pin Roll 1 8 x 9 16 Lg 1 118 BP 12190093 Assembly Cam Rod Sleeve 1 119 BP 11010513 Pin Roll 1 8 x 7 16 Lg 1 120 BP 11192053 Sprin...

Page 82: ...eeve Quill Lock Untapped 1 154 BP 12200102 Screw Rod Indicator Thumb 1 155 BP 12191620 Bolt Tee 4 156 BP 12190135 Spacer Lower Clamping Bolt 2 157 BP 12191736 Nut Hex x 1 1 2 2 158 BP 11011411 Screw Round Hd Chem Blacked 6 32 x 2 159 BP 11195306 Scale Quill Micrometer Inch 1 162 BP 12190344 Assembly Quick Nut 1 163 BP 12190082 Stop Nut Quill 1 164 BP 12190083 Stop Quill Micro Screw 1 165 BP 110110...

Page 83: ...187 BP 11013077 Key Woodruff 5 1 188 BP 11011370 Setscrew Socket Hd 1 4 UNC x 20 x 3 8 1 189 BP 12190850 Shaft Adjustable Worm 1 192 BP 12190051 Housing Quill 1 193 BP 11193111 Cup Oil 1 196 BP 12190162 Key Worm Shaft 1 8 sq x 5 16 1 Item Numbers 10 36 37 38 and 40 sold as assembly BP 12193440 Item Numbers 32 33 34 and 35 sold as assembly BP 12193544 Item Numbers 48 and 49 sold as assembly BP 1219...

Page 84: ...BASIC MACHINE 7 14 M 477A TP5344 ...

Page 85: ... 1 18 BP 11200109 Washer Chamfered and Hardened x 1 8 x 1 2 19 BP 11061180 Bolt Hex Hd Adapter Locking 0 500 13 x 7 25 3 23 BP 12060347 Table 48 Lg 1 31 BP 11061602 T Bolt Stop Piece 2 32 BP 11062301 Piece Table Stop 2 33 BP 11011720 Nut 3 8 16 Hexagon 3 34 BP 12060122 Washer 2 37 BP 12060328 Bushing Clamping 1 38 BP 12746137 Bolt Saddle Lock 1 39 BP 12060125 Plunger Saddle Lock 1 40 BP 11770252 S...

Page 86: ...Knee Binder Plastic 1 72 BP 11011375 Setscrew Dog Pt 5 16 18 x 5 16 1 73 BP 11011270 Setscrew 5 16 18 x 5 16 1 74 BP 11011755 Nut Jam 20 1 75 BP 12060071 Key 3 16 x 3 16 x 7 8 1 77 BP 11062204 Gear Bevel 1 79 BP 11060205 Bearing Fafnir W306PP3 1 80 BP 12060070 Ring Bearing Retaining 1 81 BP 11011031 Screw Socket Hd Cap 20 x 5 8 6 82 BP 12060069 Inch Elevating Screw 1 83 BP 12060060 Handle 1 84 BP ...

Page 87: ...cket Hd Cap 10 32 x 0 500 2 118 BP 12060144 Spider 1 119 BP 11060112 Stud Ram Lock 2 120 BP 12060255 Pinion Ram 1 124 BP 12060208 Turret 1 125 BP 12060137 Bar Ram Clamp 2 126 BP 12060141 Clamp Ram Blank 2 127 BP 12060113 Clamp Ram Tapped 2 128 BP 11010619 Pin Cotter 2 129 BP 11061178 Bolt Hex 13 x 5 4 130 BP 12060140 Screw Ram Pinion 1 131 BP 11060602 Scale Ram 1 BP 11980426 Drive Screw 2 132 BP 1...

Page 88: ...M 477A TP5726 20 1 2 4 5 6 3 7 8 9 10 11 12 13 14 15 16 17 18 19 Torque screws evenly to 30 lb in 3 4 Nm Torque to 50 lb ft 67 8 Nm Torque screws evenly to 30 lb in 3 4 Nm Torque to 9 lb ft 12 2 Nm Motor Force of 4lb at 0 098 deflection ...

Page 89: ...11151779 Locknut 1 9 BP 12746126 Retainer Bearing 1 10 BP 12746109 Spacer Pulley 1 11 BP 21577911 Belt HTD 560 8M 20 1 12 BP 11980227 Screw Socket Hd Cap 8 32 x 1 250 4 BP 11191920 Lockwasher 8 4 13 BP 12780491 Cover 2 BP 11665162 Screw Button Hd Cap 10 32 x 0 375 1 14 BP 64649912 Assembly Pulley 20 T 1 15 BP 12746116 Cover Bracket 1 BP 11010543 Pin Roll 3 16 x 1 2 16 BP 11011031 Screw Socket Hd C...

Page 90: ...1 000 4 4 BP 11060204 Bearing Fafnir H 204K 1 5 BP 12060214 Dial 1 6 BP 12060078 Locknut 1 7 BP 11011755 Nut Jam 20 NF 1 BP 12150164 Washer Flat 1 8 BP 12746140 Handwheel 1 9 BP 11013078 Key Woodruff 1 10 BP 12060084 Holder Dial 1 11 BP 12746209 Ballscrew X Axis 1 BP 11011075 Screw Socket Hd Cap 3 8 16 x 1 250 2 7 20 M 477A 1 2 3 4 5 6 7 8 11 9 10 TP5727 ...

Page 91: ...TY 1 BP 12060347 Table 48 1 2 BP 12060487 Saddle 1 3 BP 11011074 Screw Socket Hd Cap 3 8 16 x 1 4 4 BP 12749023 Nutblock 1 5 BP 11746208 Ballscrew 1 6 BP 11011074 Screw Socket Hd Cap 3 8 16 x 1 000 3 M 477A 7 21 1 2 3 4 5 6 TP5728 Torque to 35 lb ft 47 5 Nm ...

Page 92: ... M 477A TP5729 1 Force of 4lb at 0 162 deflection Force of 4lb at 0 187 deflection Torque evenly to 9 lb ft 12 2 Nm Torque to 50 lb ft 67 8 Nm 2 3 4 5 6 22 21 20 7 8 19 11 12 9 13 14 15 16 17 18 19 Extended Drive Compact Drive Motor ...

Page 93: ...20 1 7 BP 12060214 Dial 1 8 BP 12746143 Holder Dial 1 9 BP 12060078 Locknut 1 10 BP 12746140 Handwheel 1 11 BP 11011755 Nut Jam 20 1 12 BP 11011078 Washer Flat 1 13 BP 11665570 Screw Socket Hd Cap 5 16 18 x 0 750 4 BP 11421984 Washer 4 14 BP 11011011 Screw Socket Hd Cap 10 24 x 0 625 6 15 BP 24649915 Assembly Pulley 40 T 1 16 BP 11010210 Screw Socket Hd Cap 8 32 x 1 000 4 BP 61705552 Washer Plasti...

Page 94: ...3RD AXIS OPTION 7 24 M 477A TP6973 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 32 31 30 33 34 35 36 ...

Page 95: ...749420S19 Scale Spar Assembly 1 19 BP 11749420DS Scale 12 Differential 1 20 BP 11749420S21 Reader Head Carrier Assembly 1 21 BP 11749323 Ballscrew Assembly X 200P 1 22 BP 11749372 Ball Nut Block 3rd Axis 1 23 BP 11011834 SHCS with E Clip 1 24 BP 11749373 Spacer Tube 1 25 BP 11749322 Bearing Single Row 1 26 BP 11749375 Access Plate Assembly 1 27 BP 11749420S28 Lower Housing Assembly 1 28 BP 1174942...

Page 96: ...OPERATOR PENDANT DC150 Motion Control System 7 26 M 477A TI5563 ...

Page 97: ...POWER CASE EXTERNAL VIEW DC150 Motion Control System M 477A 7 27 TI5564 ...

Page 98: ...POWER CASE INTERNAL VIEW DC150 Motion Control System 7 28 M 477A Revised March 28 2008 TI5565A ...

Page 99: ...POWER CASE TERMINAL STRIPS DC150 Motion Control System M 477A 7 29 Revised March 28 2008 TI5566A ...

Page 100: ...ber Optic Cable 13 5 20 BP 00005490170 24VDC X Axis Power Cable 1 21 BP 00005490052 3 4 Oil Tight Hole Plug 3 22 BP 00005490053 1 2 Oil Tight Hole Plug 1 23 BP 00005490107 SS Duct DIN 1 24 BP 00092077 Cord Grip 7MM Opening 3 25 BP 000920712 Cord Grip 12MM Opening 2 26 BP 11598417 Cable Spindle Motor 1 27 BP 11598415 Cable Home Switch 1 28 BP 00005490163 X Axis Motor Cable 1 29 BP 00005490164 Y Axi...

Page 101: ...out 2 60 BP 000054940014 End Bracket Gray 6 61 BP 00005490012 Bridge 2 Position Plug In 5 62 BP 00005490003 FBS 3 5 Bridge 3 65 BP 0011032PP2 Block Terminal Partition Plate 5 66 BP 0008116TB1 Terminal Block ST 2 5 Gray 6 67 BP 00005490067 SPR solid state 208 480V 1 BP 00005490188 SPR solid state 575V 1 70 ML 0011032BU Block Terminal Blue 8 71 BP 00005490013 Terminal Ground ST2 5 6 72 BP 0000549007...

Page 102: ...3MMX438MM BLK 1 107 BP 0000549FOC Cable Fiber Optic Communication 1 108 BP 11598413 Cable Spray Mist 1 109 BP 11598888BH Motor Resolver Assembly 2 110 BP 00005490116 Kit EzVision 208 Voltage 1 111 BP 11598487208 Transformer 1 5KVA 50 60HZ 1 112 BP 000961015 Fuse 15A 600V Class J 6 113 BP 00005490117 Kit EzVision 230 240 Voltage 1 114 BP 11598487 Transformer 1 5KVA 50 60HZ 2 115 BP 00005490118 Kit ...

Page 103: ... NOTES M 477A 7 33 ...

Page 104: ......

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