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Table of Contents

INTRODUCTION

About This Machine .............................................3

Foreword

.............................................................3

Capabilities

.........................................................3

Features

..............................................................3

Full View Identification .......................................4
Drive System, Headstock,
& Control Panel Identification ............................5
Machine Specifications ........................................6

SAFETY

Understanding Risks of Machinery ....................9
Basic Machine Safety ..........................................9
Additional Milling Machine Safety ...................11

PREPARATION

Preparation Overview ........................................12
Things You'll Need .............................................12
Unpacking ..........................................................13
Inventory ............................................................13
Cleaning & Protecting .......................................14
Location ..............................................................15

Physical Environment

........................................15

Electrical Installation

........................................15

Lighting

............................................................15

Weight Load

......................................................15

Space Allocation

................................................15

Lifting & Moving ................................................16
Leveling & Mounting .........................................17

Leveling

............................................................17

Bolting to Concrete Floors

..................................17

Assembly ............................................................18

Ball Handles

......................................................18

Z-Axis Crank

.....................................................18

Way Covers .....................................................18

Splash Pan & Coolant Return Hoses

..................19

Initial Lubrication .............................................20
Power Connection ..............................................20
Test Run .............................................................21
Spindle Break-In ................................................24
Inspections & Adjustments ...............................24

OPERATION

Operation Overview ...........................................25
Control Panel .....................................................26
Table Movement.................................................27

Table Locks

.......................................................27

Graduated Index Rings

......................................27

X-Axis Power Feed

.............................................28

Head Movement .................................................29

Tilting Head

......................................................29

Rotating Head

...................................................30

Tramming Spindle

.............................................30

Ram Movement ..................................................33

Moving Ram Back and Forth

..............................33

Rotating Ram

....................................................33

Setting Spindle Speed ........................................34

Determining Spindle Speed

................................34

Setting Spindle Speed Range

.............................34

Setting Spindle Speed

........................................35

Downfeed Controls .............................................35

Using the Coarse Downfeed Handle

...................35

Fine Downfeed Controls

.....................................37

Using the Fine Downfeed Handwheel

.................37

Using the Auto-Downfeed System

......................38

Spindle Brake .....................................................39
Loading/Unloading Tooling ...............................40

Loading Tooling

.................................................40

Unloading Tooling

.............................................40

MAINTENANCE

Maintenance Schedule .......................................41

Ongoing

.............................................................41

Machine Storage ................................................41

Before Beginning Operations

.............................41

Daily, After Operations

......................................41

Cleaning .............................................................43

Unpainted & Machined Surfaces

........................43

Lubrication .........................................................43

Quill

..................................................................44

Table Ways (One-Shot Oiler)

..............................44

Speed Range Bearing Sleeve

..............................45

Headstock Gearing

............................................45

Ram Ways

.........................................................45

Head & Ram Rack & Pinion Gear

......................45

Table Elevation Leadscrew

................................46

Power Feed Gears

..............................................46

Coolant Reservoir...............................................48

Checking Coolant Level

.....................................48

Changing Coolant

..............................................49

Machine Storage ................................................50
Adjusting Gibs....................................................50

Содержание SB1027

Страница 1: ...reds of Thousands of Lathes Sold With a Tradition of Quality Since 1906 Copyright April 2010 For Machines Mfg Since 8 09 MODEL SB1027 9 X 48 EVS MILLING MACHINE w COOLANT SYSTEM POWER FEED OWNER S MAN...

Страница 2: ...tion is a process that happens through training and experience If you are not an experienced operator of this type of machinery read through this entire manual then learn more from an experienced oper...

Страница 3: ...anel 26 Table Movement 27 Table Locks 27 Graduated Index Rings 27 X Axis Power Feed 28 Head Movement 29 Tilting Head 29 Rotating Head 30 Tramming Spindle 30 Ram Movement 33 Moving Ram Back and Forth 3...

Страница 4: ...TING 54 ELECTRICAL Electrical Safety Instructions 56 Upper Electrical Panel 57 Lower Electrical Panel 58 Control Panel Wiring 59 Electrical Component Pictures 60 PARTS Headstock 61 Quill 64 Gearbox 65...

Страница 5: ...e television set mechanical calculator computer and camera of that decade could barely fit into one large room together now they fit into a tiny box that is no bigger than a box of breath mints And th...

Страница 6: ...entification Drive System Headstock See Page 5 for Identification Coolant Nozzle Valve X Axis Ball Handle Coolant Return Hose One Shot Oiler Z Axis Crank Y Axis Ball Handle X Axis Power Feed Power Fee...

Страница 7: ...e manual and received proper training Drive System Headstock Control Panel Identification Figure 2 SB1027 drive system and headstock identification Motor Belt Tension Adjustment Lever Belt Housing Spi...

Страница 8: ...Single Phase 60 Hz Phase Inverter Yaskawa V1000 Switch Magnetic Switch w Thermal Overload Protection Switch Voltage 220V Minimum Circuit Size 15 Amp Recommended Power Cord 14 Gauge 3 Wire 300 VAC Plug...

Страница 9: ...teel 3 4 Number of Spindle Speeds Variable Range of Spindle Speeds 60 5000 RPM Number of Longitudinal Feed Rates Variable Longitudinal Feed Rate Range 0 31 3 FPM Quill Diameter 3 375 Number of Quill A...

Страница 10: ...tup Cleaning Time 1 2 Hours Features High Quality Low Vibration AEVF Spindle Motor P4 ABEC 7 High Quality Angular Contact Spindle Bearings Powered Recycling Coolant System X Y Leadscrew Nuts Double Br...

Страница 11: ...Death or catastrophic harm WILL occur Moderate injury or fire MAY occur Death or catastrophic harm COULD occur Machine or property damage may occur Basic Machine Safety 1 Owner s Manual All machinery...

Страница 12: ...verifying that all fastening devices are properly secured and items attached to spindles have enough clearance to safely rotate 11 Chuck Keys or Adjusting Tools Tools used to adjust spindles chucks or...

Страница 13: ...g results and reduces the risk of personal injury from broken tool debris Inspect cutting tools for sharpness chips or cracks before each use and ALWAYS make sure the cutting tools are firmly held in...

Страница 14: ...with any API GL 2 grease Stiff grease brush Phillips dcrewdriver 2 Floor mounting hardware as needed Hex wrench 5mm Hex wrench 6mm Combo wrench 1 2 or ratchet and 1 2 socket The purpose of the prepara...

Страница 15: ...oved from the shipping crate you should have the following inventory Description Figure 3 Qty A Front Way Cover 1 B Rear Way Cover 1 C Fine Downfeed Handwheel 1 D Drawbar 7 16 20 x 181 2 1 E Ball Hand...

Страница 16: ...gh test them on an inconspicuous area of a painted area to make sure they will not damage it Basic steps for removing rust preventative 1 Put on safety glasses and disposable gloves 2 Coat all surface...

Страница 17: ...nt The physical environment where your machine is operated is important for safe operation and longevity of parts For best results operate this machine in a dry environment that is free from excessive...

Страница 18: ...5 refer to Ram Movement on Page 33 and Headstock Movement on Page 29 for detailed instructions Note After re positioning the ram and headstock make sure they are locked in place to prevent unexpected...

Страница 19: ...nsitive enough to show a distinct movement when a 0 003 shim approximately the thickness of one sheet of standard newspaper is placed under one end of the level See the figure below for an example of...

Страница 20: ...the leadscrew key then slide it onto the X axis leadscrew 4 Secure the ball handles with the hex nuts removed in Step 1 Note Tighten the hex nuts just until they are snug Overtightening could increas...

Страница 21: ...n in Figure 12 from the base rim slide the splash pan into position then secure it with the removed cap screws 2 Use Teflon tape or pipe sealant on the threads of the pipe elbows then install them int...

Страница 22: ...and assembled as previously described in this manual it is ready to be connected to the power source Note About Required Power Source The milling machine is equipped with a Yaskawa phase inverter tha...

Страница 23: ...is mill without the correct amount of coolant in the reservoir could damage it and void the warranty ALWAYS make sure there is the correct amount of coolant in the reservoir before using the pump 2 Cl...

Страница 24: ...WITHOUT resetting the emergency STOP button press the ON button The machine should not start If the machine does not start the emergency STOP button safety feature is working correctly If the machine...

Страница 25: ...tools cables and other items are well clear of table movement as you follow these steps 2 Refer to the Table Movement section beginning on Page 27 to understand how the power feed table locks and lim...

Страница 26: ...re trouble free performance from the mill To perform the spindle break in procedure 1 Successfully perform all the steps in the Test Run section beginning on Page 21 2 Make sure the spindle is at a co...

Страница 27: ...he correct positioning of the cutting tool and workpiece for the operation If the X axis power feed will be used during the operation the operator confirms the speed and length of table movement requi...

Страница 28: ...er to flow to the mill s electrical components Coolant Switch Turns coolant pump ON and OFF Spindle Direction Switch Starts stops and reverses spindle rotation Spindle Speed Dial Controls the spindle...

Страница 29: ...ed Index Rings The table ball handles and elevation crank have graduated index rings attached see Figure 21 that are used to accurately determine table movement in the increments listed in the table b...

Страница 30: ...th one full revolution equal to 0 200 of table travel To confirm the power feed settings that you will be using during operation we recommend that you use the power feed to move the table through the...

Страница 31: ...e tilt lock bolts on the right side of the ram adapter shown in Figure 25 3 Use one hand to apply pressure to the head in the direction of the tilt then slowly rotate the tilt bolt Rotating this bolt...

Страница 32: ...ensure the spindle is exactly 90 to the table This procedure involves mounting a dial test indicator to the quill or spindle rotating it around the table and adjusting the spindle axis Z axis 90 to t...

Страница 33: ...sks Stone the table to remove all nicks and burrs then clean off all debris Verify the table is clean by running your hand over the top of it Position the table for the milling operation you intend to...

Страница 34: ...y during the process of re tightening the lock bolts 9 Place the parallel block directly under the spindle and across the width of the table as illustrated in Figure 30 Note Generally the goal in the...

Страница 35: ...se will move the ram backward 4 Re tighten the lock levers after you have re positioned the ram Rotating Ram 1 DISCONNECT MILL FROM POWER 2 Loosen the four lock bolts on top of the turret see Figure 3...

Страница 36: ...the correct spindle speed is important for safe and satisfactory results as well as maximizing tool life To set the spindle speed for your operation you will need to 1 Determine the best spindle spee...

Страница 37: ...e and the bottom values are for the low range Downfeed Controls Spindle downfeed movement on the mill is controlled by three mechanisms 1 The coarse downfeed handle 2 the fine downfeed handwheel and 3...

Страница 38: ...ake sure the pin of the coarse downfeed handle hub is engaged with one of the detents on the downfeed sleeve see Figure 38 5 Make sure the quill lock lever is loose so that the quill can easily move 6...

Страница 39: ...eel is used to secure it in place H Quill Dog Moves with the quill and spindle and disengages the downfeed clutch lever when it meets either the top or downfeed stop I Downfeed Selector Sets the mill...

Страница 40: ...correct for your operation It may be necessary to rock the fine downfeed handwheel back and forth to move the pin all the way in or out Note The direction pin has three positions 1 In for one downfee...

Страница 41: ...ightly until you can pull the clutch lever out to the left and it locks in place which will start the auto downfeed spindle travel To avoid the risk of gear damage always start spindle rotation before...

Страница 42: ...ding pin inside the spindle taper then firmly push the tool into the spindle to seat it 5 With one hand holding the tool in place insert the drawbar into the spindle from the top of the head then thre...

Страница 43: ...cy Coolant not flowing correctly Any other unsafe condition Before Beginning Operations Make sure the electric box door is closed and properly latched Turn the spindle direction switch to the STOP mid...

Страница 44: ...eep each charts as a maintenance record for the mill 360 734 1540 FAX 360 676 1075 www southbendlathe com South Bend Lathe Co Monthly Maintenance Chart for Model SB1027 Milling Machine 1 2 3 4 5 6 7 8...

Страница 45: ...0 hrs 45 Table Elevation Leadscrew Z Axis 40 hrs 46 Power Feed Gears 160 hrs 46 Figure 45 Recommended lubrication tasks schedules and instruction page references Cleaning Regular cleaning is one of th...

Страница 46: ...able through all paths of movement to evenly distribute the lubricant Use the sight glass on the side of the oiler to know when to re fill the reservoir Figure 47 One shot oiler controls Pump Handle S...

Страница 47: ...tting Ram Ways Oil Type Mobil Vactra 2 or ISO 68 Equivalent Oil Amount Thin Coat Check Add Frequency 40 hrs of Operation Move the ram back and forth as necessary to access the full length of the ways...

Страница 48: ...ess until the entire leadscrew is covered with a thin coat of lubricant Power Feed Gears Grease Type Medium Weight Lithium Grease Grease Amount Two Pumps of Grease Gun Check Add Frequency 40 hrs of Op...

Страница 49: ...he bevel gear keyway with the key as you slide the gear onto the leadscrew and mesh its teeth with the drive gear 7 Replace the graduated dial ring into position and secure it with the knurled retaini...

Страница 50: ...ning the coolant pump without adequate coolant in the reservoir may permanently damage the coolant pump This action is considered abusive and is not covered by the warranty 3 If the level of coolant i...

Страница 51: ...ls Needed Qty Hex Wrench 3mm 1 Hex Wrench 5mm 1 Catch Pan 1 Bucket 5 Gal 1 To change the coolant 1 Put on personal protective equipment 2 Place a the catch pan on the table position the coolant nozzle...

Страница 52: ...t screws Machine Storage To avoid rust problems or corrosion damage use the following information to protect your investment when storing the mill for any length of time DISCONNECT MILL FROM POWER Lub...

Страница 53: ...crew rotates before the attached device begins to move Although the mill is equipped with double bronzed longitudinal and cross leadscrew nuts to minimize backlash leadscrews will always have a certai...

Страница 54: ...Longitudinal Leadscrew Backlash 1 DISCONNECT MILL FROM POWER 2 Loosen the two cap screws on the leadscrew nut accessed from underneath the left side of the table as shown in Figure 61 Figure 61 Longi...

Страница 55: ...stall the parts previously removed in the reverse order Belt Tensioning Figure 65 Belt tensioning controls Tension Adjustment Lever Motor Mount Cap Screw 1 of 2 Adjustment Cap Screw Power is transferr...

Страница 56: ...cutting tool for the operation 4 Spindle speed is incorrect for the operation 4 Select appropriate spindle speed Page 34 5 Motor connection wired incorrectly 5 Correct motor wiring connections Page 5...

Страница 57: ...the tool replace if damaged 4 Spindle speed too fast feed rate too slow 4 Use correct spindle speed and feed rate Page 34 5 Gibs are too loose 5 Properly adjust gibs Page 50 Table hard to move 1 Tabl...

Страница 58: ...s including serious injury or fire 4 Motor Wiring The motor wiring shown in these diagrams is current at the time of printing but it may not match your machine Always use the wiring diagram inside the...

Страница 59: ...40 Ohm Thermal Brake Resistor Variable Frequency Drive Yaskawa V1000 CIMR VT2A0020BAA 200V 3 Ph 5 5kW 3 7kW U V W 6 8 13 7 12 11 10 R1 T1 B1 B2 T1 8 13 R1 freq drive wiring To Control Panel Page 59 To...

Страница 60: ...35 U2 W2 L1 L3 20A Fuse 20A Fuse 2T1 4T2 6T3 8T4 2T1 4T2 6T3 8T4 110V 5 15 Outlets T T R2 R2 T2 T2 R R R R T T T T 2R 0 0 0 0 0 0 1 2 3 4 5 9 30 34 35 L1 L3 30 1 20 20 33 33 5 2 13 13 8 8 3 9 34 35 4...

Страница 61: ...Dial Spindle Speed Display X2 X1 3 NO 4 1 2 2 2 11 11 10 9 7 6 5 4 3 5 4 1 2 3 0 2 9 12 12 10 S Capacitor 3M 450V Rd Rd Rd Rd Yl Yl Yl X1 Y1 Z1 U2 V2 W2 U1 V1 W1 W W 34 35 V U 2 2 3 3 Ground component...

Страница 62: ...Model SB1027 E L E C T R I C A L Electrical Component Pictures Figure 66 Control panel wiring Figure 68 Spindle motor wiring Figure 69 Spindle brake switch wiring Figure 70 Coolant pump motor wiring F...

Страница 63: ...50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 1...

Страница 64: ...R CRADLE THROW OUT 71 PSB10240071 OVERLOAD CLUTCH WORM GEAR 30T 25 PSB10240025 WORM SHAFT 72 PR05M EXT RETAINING RING 15MM 26 PSS01M SET SCREW M6 1 X 10 73A PSB10240073A PINION OVERLOAD CLUTCH ASSY 27...

Страница 65: ...127A KNURLED SLEEVE 106 PCAP105 CAP SCREW 3 8 16 X 5 8 128 PSB10240127A HANDWHEEL CAPTIVE PIN 107A PSB10240107A STOP TRIP BAR ASSEMBLY 129 PSB10240129 QUILL LOCK NUT 107 PSB10240107A STOP SHAFT TRIP B...

Страница 66: ...B10240211 SPANNER NUT 203 PSB10240203 QUILL END CAP 212 PSB10240212 QUILL SKIRT 204 PSB10240204 QUILL SEAL 213 PSS26M SET SCREW M5 8 X 6 205 PSB10240205 ANGULAR CONTACT BEARING 7207 P4 214 PSB10240214...

Страница 67: ...65 P A R T S Gearbox 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 339 340 341 342 343 344 345 346 347 348...

Страница 68: ...5 X 14 308 PSB10240307A BULL GEAR BEARING SPACER 334 PK14M KEY 5 X 5 X 18 309 PR38M INT RETAINING RING 62MM 335 PZERK005 GREASE FITTING ST 1 8 PT 310 PSB10240310 SPACER 336 PSB10240336 GEARBOX HOUSING...

Страница 69: ...405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437 438 439 440 441 442 443 444 445 446 447 448 449 450 451 452 453 454...

Страница 70: ...0270447 CAPTIVE PIN 414 PCAP12M CAP SCREW M8 1 25 X 40 448 PSB10240456 BRAKE LEVER 415 PSS26M SET SCREW M5 8 X 6 449 PSB10240449 KNOB 3 8 16 416 PSB10270416 TOP BEARING COVER 450 PSB10240458 BRAKE OPE...

Страница 71: ...M ADAPTER 525 PSB10240524 RAM PINION SCREW 507 PSB10240017 INDICATOR PLATE 526 PSB10240525 TURRET 508 PSB10240508 WORM THRUST WASHER 527 PSB10240526 RAM GIB ADJUSTMENT SCREW 509 PSB10240509 LOCK COLLA...

Страница 72: ...615 616 617 618 619 620 621 622 623 624 625 626 627 628 629 630 631 632 633 634 635 636 637 638 639 640 641 642 643 644 645 646 647 648 649 650 651 652 653 654 655 656 657 658 659 660 661 662 663 664...

Страница 73: ...PINION 616 PSB10240616 LOWER KNEE LOCK PLUNGER 650 PSS03M SET SCREW M6 1 X 8 617 P51305 THRUST BEARING 51305 651A PSB10240651A CHIP GUARD SET 618 PK20M KEY 5 X 5 X 15 651 PSB10240651A OUTER CHIP GUARD...

Страница 74: ...704 705 706 708 709 710 711 707 712 713 714 715 716 717 718 719 720 721 722 735 736 737 738 739 740 741 742 743 744 745 746 747 748 749 750 751 752 753 715 716 717 718 719 720 721 722 701 702 723 724...

Страница 75: ...PCAP06M CAP SCREW M6 1 X 25 712 PSB10240712 CROSS FEED BEARING BRACKET 739 PW03M FLAT WASHER 6MM 713 PK92M KEY 3 X 3 X 25 740 PSB10240714A FRONT CROSS LEADSCREW NUT 714A PSB10240714A CROSS FEED LEADS...

Страница 76: ...D E F G H K 801 K REF PART DESCRIPTION REF PART DESCRIPTION 801 PSB10240801 ELBOW JOINT M4 X 1 8 PT 805 PCAP01M CAP SCREW M6 1 X 16 802 PSB10240802 T JOINT 806 PSB10240806 FLEXIBLE STEEL TUBE 4 X 500M...

Страница 77: ...903 COOLANT PUMP 1 8HP 220V 1PH 60HZ 912 PSB10270912 COOLANT NOZZLE 3 8 X 30 IN 904 PSB10270904 BARBED HOSE FITTING 3 8 PT X 1 2 IN 913 PSB10270913 PIPE ELBOW 90 DEG 3 8 PT X 1 2 IN 905 PSB10270905 TH...

Страница 78: ...Mfg Since 8 09 Model SB1027 P A R T S Electric Box Control Panel 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 1021 1022 1023 1024 1025 1026 1027...

Страница 79: ...2 RELAY SOCKET OMRON 1007 PSB10271007 RELAY OMRON MYA1 24V 1023 PSB10271023 EMERGENCY STOP BUTTON 1008 PSB10271008 CONTACTOR AB C09 400 220V 1024 PSB10271024 SPINDLE MOTOR ON BUTTON 1009 PSB10271009 E...

Страница 80: ...1105 1106 1107 REF PART DESCRIPTION REF PART DESCRIPTION 1101 PSB10241004 TOOLBOX 1105 PWR1921C CLOSED WRENCH 19 21MM 1102 PSDF2 SCREWDRIVER FLAT 2 1106 PAW1510M HEX WRENCH 10PC 1 5 10 MM 1103 PSDP2 P...

Страница 81: ...6 PSB10271206 MACHINE ID LABEL 1214 PSBPAINT03 SB DARK BLUE TOUCH UP PAINT 1207 PSB10271207 CONTROL PANEL LABEL 1215 PSBPAINT 02 SB LIGHT BLUE TOUCH UP PAINT 1208 PSB10241105 DOWNFEED SELECTOR LABEL 1...

Страница 82: ...02HL DISCONNECT WARNING LABEL 1220 PSB10271220 SPEED RANGE LABEL 1210 PSBLABEL13HL CLOSE DOOR WARNING LABEL 1221 PSB10271221 220V 1PH LABEL 1217 PSB10241112 POWER FEED CAUTION LABEL 1222 PSB10271222 B...

Страница 83: ...machine complies with the provisions of any law act code regulation or standard of any domestic or foreign government industry or authority In no event shall South Bend s liability under this warranty...

Страница 84: ...South Bend Lathe Co P O Box 2027 Bellingham WA 98227 PHONE 360 734 1540 Administrative Offices FAX 360 676 1075 International FAX 360 734 1639 USA only southbendlathe com Printed In Taiwan JBTS12256...

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