Bridgeport Series I Installation, Operation, Maintenance, And Parts List
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Bridgeport Series I Installation, Operation, Maintenance, And Parts List

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INSTALLATION, OPERATION,
MAINTENANCE, AND PARTS LIST
SERIES I
MILLING MACHINES
TP5260
Revised: May 21, 2010
Manual No. M-450A
Litho in U.S.A.
Part No. M A-0009500-0450
March, 2009

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  • Page 1 INSTALLATION, OPERATION, MAINTENANCE, AND PARTS LIST SERIES I MILLING MACHINES TP5260 Revised: May 21, 2010 Manual No. M-450A Litho in U.S.A. Part No. M A-0009500-0450 March, 2009...
  • Page 2 B. Page Number. C. Item Number. D. Part Description. E. Part Number. F. Quantity of each part required. 3. Specify how and where to ship. - NOTICE - Bridgeport is a registered trademark of Hardinge Inc. © 2009, Hardinge Inc. M-450A...
  • Page 3 SAFETY To prevent serious bodily injury, you should observe the following basic safety precautions when installing, operating or servicing the milling machine. 1. Follow all instructions in the manual. 2. Wear approved industrial safety glasses and safety shoes. 3. Do not wear gloves, long sleeves, long hair, rings, watches, jewelry or other items that could become caught in moving parts.
  • Page 4 WARNINGS, CAUTIONS, AND NOTES - WARNING - Warning notices are used in this publication to emphasize that hazardous mechanical conditions, voltages, currents, or temperatures exist in this equipment which could cause serious personal injury and/or damage to the equipment. - CAUTION - Caution notices are used where equipment might be damaged if care is not taken.
  • Page 5 SAFETY RECOMMENDATIONS DO NOT OPERATE EQUIPMENT until you have read and understood the appropriate opera- tor and safety maintenance manuals. DO NOT OPERATE EQUIPMENT until you have read and understood all machine and con- trol key signs. DO NOT OPERATE EQUIPMENT for the first time without a qualified instructor. Consult your supervisor when in doubt as to the correct way to perform an operation.
  • Page 6 PROTECT YOUR HANDS. Stop the machine before changing or adjusting belts, pulleys or gears. PROTECT YOUR HANDS. Keep hands and arms clear of spindle start switch when changing tools. PROTECT YOUR EYES AND THE MACHINE. Never use a compressed air hose to remove chips.
  • Page 7 INSTALLATION AND USE OF SAFEGUARDS Both American National Standard B11.8 and OSHA Section 1910.212 assign responsibility for point of operation safeguarding of milling machines to the employer/user. Therefore, to prevent serious injury resulting from the rotating cutter, flying chips, or splashing coolant, point of operation safeguarding should be used on milling machines to the greatest extent practicable.
  • Page 8 GENERAL PURPOSE SAFEGUARDS There is no single safeguard which can match the versatility of the Series I machine. As a result, you will find that the guard assemblies shown in Figures I.I and I.II, like all safeguards, will be suitable for some operations, but not for others.
  • Page 9 Machines with Erickson #30 Quick Change or Universal #200 Quick Change Spindles If the machine was manufactured after January 1, 1985 and has either an Erickson #30 or a Universal #200 quick change spindle, the manufacturer has drilled and tapped four #8-32 holes in the nose cap of the spindle for mounting the guard.
  • Page 10 BP 11060813 – R-8 Shield Assembly Refer to Figure I.I. Item Part Number Description BP 11191203 Shield Assembly, Rear BP 11010060 Screw, Hand 8-32 x .500 0300312 Screw, BHC 10-32 x .750 BP 11010065 Washer, Plastic #10-32 BP 11010055 Nut, Stop, #10-32 (Elastic) BP 11060824 Shield, Right Side BP 11060817...
  • Page 11 - NOTES - M-450A...
  • Page 12 - NOTES - M-450A...

  • Page 13: Table Of Contents

    Table of Contents CHAPTER 1 - INSTALLATION Uncrating ........1-1 Shortages .
  • Page 14 Machine........2-14 Operational Procedures ......2-14 Swivel the Belt Housing .
  • Page 15 2J Milling Head (2 HP) – Spare Parts Kit ....4-48 Series I Standard Machine – Spare Parts Kit ....4-49 Lead Screws for Manually Operated Machines (without Keys) .
  • Page 16 CHAPTER 5 - SPECIFICATIONS Machine........5-1 Principle Dimensions .

  • Page 17: Chapter 1 - Installation

    CHAPTER 1 - INSTALLATION UNCRATING Carefully remove protective crating and skids so that the machine and parts are not marred, scratched or impaired. In the event of damage having occurred during transit, communicate at once with our representative and the transportation company making delivery. SHORTAGES Check shipment carefully against the itemized packing list which is included in the parts box.

  • Page 18: Positioning The Head Upright

    POSITIONING THE HEAD UPRIGHT If delivery of your machine is made with the milling head in an upside-down position, follow the instructions below to prepare your machine for operation. For shipping purposes, the hand cranks are inverted to face the machine. To reverse them, engage the lock mechanism to the saddle and table.
  • Page 19 TP5280 Figure 1.4 - Tightening Sequence M-450A...

  • Page 20: Lifting The Machine

    LIFTING THE MACHINE - WARNING - BE SURE to use proper sling when lifting. improper lifting could cause seri- ous injury. Note position of ram and table when lifting with sling. Machine should be lifted by placing a sling under the ram as illustrated in Figure 1.5. TP5279 Figure 1.5 - Lifting the Machine M-450A...

  • Page 21: Foundation

    FOUNDATION PLACING ON A SOLID FOUNDATION When setting machine on a concrete foundation, it is advisable to use a little grout (thin mortar) to take care of any unevenness in the concrete as well as to provide a solid foundation at all points. When setting machine on a floor than has any surface irregularities, shims should be used to correct this condition to the greatest extent possible.

  • Page 22: Leveling The Machine

    LEVELING THE MACHINE Set machine by leveling the work table lengthwise and crosswise with a precision instrument as shown in Figure 1.7. Level Level TP5282 Figure 1.7 - Leveling the Machine M-450A...

  • Page 23: Machine Power Supply

    MACHINE POWER SUPPLY - WARNING - MACHINE MUST be hooked up by a qualified electrician. CONNECTING THE POWER SUPPLY To connect the machine to the plant supply, have a qualified electrician proceed as follows: 1. Check required voltage against power supply to ensure that they are compatible. 2.

  • Page 24: Lubrication

    LUBRICATION Lubrication Instruction Plate Recommended Lubrication Few Drops Twice Daily TP5283 Figure 1.8 - Lubrication Requirements Indicator Lubrication Area Type of Lubrication Way Surfaces and Lead Screws Sunoco Waylube #1180 or equivalent S.A.E. 10 or 10W Light Oil Milling Heads (Spindle Bearings) (None on grease-packed heads) Motor None required.

  • Page 25: Alignment Of The Head For Fine Work

    ALIGNMENT OF THE HEAD FOR FINE WORK For precision boring or work of that nature, where it is necessary to have the head perfectly square with the table, use method described below. To set head perfectly square with table, adjust ram adapter through vertical adjusting worm shaft with ram adapter on ram.
  • Page 26 - NOTES - 1-10 M-450A...

  • Page 27: Chapter 2 - Operation

    CHAPTER 2 - OPERATION HEAD CONTROLS TP5285 Figure 2.1 - Head Controls Parts Assembly M-450A...

  • Page 28: High-Low Range Switch

    HIGH-LOW RANGE SWITCH High-Low Range Switch “A”, Figure 2.2, is a motor reversing switch. When the attachment is in direct drive (HIGH SPEED), the motor and spindle are turning in a clockwise direction as viewed from the top of machine. When the attachment is in “Back Gear”...

  • Page 29: Spindle Brake

    SPINDLE BRAKE Spindle Brake “C”, Figure 2.4, can be moved in either direction to stop spindle; however, when locking spindle, brake lever should be moved either by pulling towards the operator or pushing away from the operator, then raised. When brake is worn out it has to be replaced.

  • Page 30: Quill Stop Knob

    QUILL STOP KNOB Quill Stop Knob “E”, Figure 2.6, is used to disengage automatic feed in either direction as well as the stop point setting working depths. MICROMETER NUT Micrometer Nut “F”, Figure 2.6, is used for setting depths. Each graduation on nut indicates .001” of depth, it reads directly to scale mounted along the side of it.

  • Page 31: Feed Control Lever

    FEED CONTROL LEVER Feed Control Lever “I”, Figure 2.8, engages overload clutch on pinion shaft when positioned left and will stay engaged until either quill stop comes in contact with micrometer adjusting nut, forcing feed control lever to drop out automatically, or release manually by engaging lever to right.

  • Page 32: Quill Feed Handle

    QUILL FEED HANDLE Quill Feed Handle “M”, Figure 2.10, is used to raise and lower the quill manually. It is generally recommended that handle be engaged when using the power feed. It may be removed by simply pulling handle off. TP5294 Figure 2.10 - Quill Feed Handle POWER FEED TRANSMISSION ENGAGEMENT...

  • Page 33: Hi-Neutral-Lo Lever

    HI-NEUTRAL-LO LEVER The Hi-Neutral-Lo Lever “O”, Figure 2.13, is used to put the attachment into either back gear or direct drive. Rotate the spindle by hand to facilitate meshing of clutch or gears. Neutral is provided to permit free spindle rotation for indicating and setup work. In the high speed position (direct drive) the spindle is driven by tapered clutch teeth.

  • Page 34: Speed Change Handwheel

    SPEED CHANGE HANDWHEEL - CAUTION - DO NOT attempt to change spindle RPM unless the motor is running. Dial speeds will only be approximate. Belt wear will cause a slight variation in speeds from what is indicated on the dial. Spindle speeds are adjusted by turning Speed Change Handwheel “P”, Figure 2.14, on the front of the belt housing.

  • Page 35: Motor

    MOTOR Motor “Q”, Figure 2.15, has the following specifications: • 2 HP variable speed (with 2J head) • 3 HP 30 minute duty rate DRAWBAR When tightening or loosening the Drawbar “R”, Figure 2.15, it is necessary to lock the spindle. To accomplish this, use the spindle brake which is located on the left side of the belt housing, pulling towards the operator or pushing away from the operator until it binds, then raise the quill feed handle.

  • Page 36: Operational Procedures

    OPERATIONAL PROCEDURES Spindle Speed - CAUTION - DO NOT change speed when spin- dle is stationary. Change speed only when spindle is running. To change speed within range: 1. Start spindle. 2. Turn handwheel “A”, Figure 2.16, to select required speed. TP5300 Figure 2.16 - Spindle Speed Change Back Gear (Low Speed)

  • Page 37: Direct Drive (High Speed)

    Direct Drive (High Speed) To change range from back gear to direct drive: 1. Switch “B” to OFF (Stop spindle rotation). 2. Move lever “C”, Figure 2.18, through neutral to HIGH. High 3. Rotate spindle by hand until the clutches are felt to engage.
  • Page 38 AUTOMATIC FEED - NOTE - Maximum loading .375” (9.5mm) diameter drill steel. 1. Ensure quill lock “G”, is off. 2. Set micrometer dial “H” to required depth. 3. Engage auto quill feed “D” when motor has stopped 4. Select feed rate “I”. 5.

  • Page 39: Head

    HEAD OPERATIONAL PROCEDURES Spindle Brake Brake lever has capability to rotate in either Brake direction to brake and lock. 1. CAM upwards to lock and prevent movement of spindle (see Figure 2.21). Brake Turn and Lift to Lock TP5306 Figure 2.21 - Spindle Brake Quill Sensitive Hand Feed 1.

  • Page 40: Machine

    MACHINE OPERATIONAL PROCEDURES Swivel the Belt Housing - CAUTION - Incorrect spline alignment can be caused by unequal tightening of the locknuts ’J’ causing fluctuation of the quill feed which can be felt through the sensitive feed handle. It is advised to call Hardinge service department before attempting this procedure.

  • Page 41: Move The Ram Slide

    Move the Ram Slide 1. Use wrench provided with machine to loosen bolts “L” and “M”, Figure 2.25. 2. Use wrench to move the slide to the desired position using bolt “N”. Rear 3. Tighten bolts “L” and “M”, starting with the rear bolt.

  • Page 42: Knee Clamping

    Table Clamping The table clamp levers are located on front of saddle and should always be clamped when longitudinal movement is not required (see Figure 2.28). Lock Unlock Table Clamp Levers TP5311 Figure 2.28 - Table Clamping Knee Clamping The knee clamping levers are at the left side of the knee and front of knee. Leave clamped at all times unless using knee in operation (see Figure 2.27).

  • Page 43: Power Feed Controls

    POWER FEED CONTROLS OPERATIONAL PROCEDURES Variable Table Feeds Power Feed (X-Axis) Table Feed Engage Lever Feed Left Neutral Feed Right TP5313 Figure 2.29 - Variable Table Feeds Quick-Release Safety Handle Grip handle and turn to either left or right until spring loaded plunger engages in position. - NOTE - Ball crank handle is a safety device.

  • Page 44: E-Head Controls

    E-HEAD CONTROLS OPERATIONAL PROCEDURES Head Swivel 1. Loosen the four locknuts (see Figure 2.33). Support unit to prevent free fall. 2. Swivel to required angular setting. 3. Tighten the four locknuts first to 25 lb-ft. Then 50 lb-ft (ref. Page 1-3). - NOTE - Remove the screw sealing vent hole before operating machine (ref.

  • Page 45: To Change The Speed

    To Change the Speed 1. Disconnect power from head. 2. Loosen the two motor locknuts (see Figure 2.34). 3. Slide motor forward. 4. Position vee belt on appropriate pulleys. 5. Slide motor to rear to tension vee belt. 6. Tighten the two motor locknuts. With 50 cycle 1425 rpm 60, 85, 120, 170, 245 350 strokes per minute.

  • Page 46: Clapper Box

    Clapper Box To Swivel Clapper Box: 1. Loosen the two set screws “O”, Figure 2.36. 2. Rotate to the required angular setting. 3. Tighten the two set screws “O”. Tool Relief 1. Loosen set screw “P”. Rear View The tool will now have automatic relief on the return stroke.
  • Page 47 - NOTES - M-450A 2-21...
  • Page 48 - NOTES - 2-22 M-450A...

  • Page 49: Chapter 3 - Maintenance

    CHAPTER 3 - MAINTENANCE 2J-HEAD MOTOR REMOVAL 1. Run head to adjust to lowest speed. 2. Disconnect power. 3. Remove three screws “A” and cover “B”, Fig- ure 3.1. 4. Using the two screws “A”, compress spring “C”. 5. Rotate the speed changer to the highest speed.

  • Page 50: Drive Belt Replacement

    DRIVE BELT REPLACEMENT 1. Remove the motor as described on Page 3-1. 2. Remove the three screws “F”, Figure 3.3, insert into the adjacent tapped holes and withdraw bearing housing “G”. 3. Remove the two screws and the bushings “H”. 4.

  • Page 51: Brake Shoe Replacement

    BRAKE SHOE REPLACEMENT 1. Remove the top section. 2. Remove the two screws “P”, Figure 3.5. 3. Remove the clutch hub assembly “Q”. 4. Replace the brake shoes “R”. 5. Remove the bearing, drive discs and circlips from the hub assembly “Q”. 6.

  • Page 52: Head

    HEAD MICRO FEED TRIP ASSEMBLY AND QUILL REMOVAL 1. Remove screw “A” and ball reverse lever “B”, Figure 3.6. 2. Remove retaining ring “C”, screw “D” and arm “E”. 3. Thread shaft “F” through micro nuts and re- move. 4. Remove screw “G” and stop “H”. 5.

  • Page 53: Balance Spring Replacement

    BALANCE SPRING REPLACEMENT 1. With quill in maximum up position apply quill lock. 2. Remove screw “I”, hub “J”, and key “K”, Fig- ure 3.7. 3. Remove screws “L”, allowing housing to ro- tate slowly releasing spring tension. 4. Lift end of spring from pin on the pinion shaft.

  • Page 54: Collet Aligning Screw Replacement

    COLLET ALIGNING SCREW REPLACEMENT 1. Use felt pen, mark reference line on quill and nose cap “S”, Figure 3.9. 2. Remove set screw “R”. 3. Unscrew nose cap “S”. 4. Remove lock screw “T” and collet aligning screw “U”. 5. Replace “U”; insert collet and check that the dog on the end of the screw does not interfere with the bottom of the guide slot.

  • Page 55: Gib Strip Adjustment

    GIB STRIP ADJUSTMENT ADJUSTMENT OF THE TABLE GIB The table is provided with a full length tapered gib Table Gib in the saddle, and an adjusting screw on the left side Screw (see Figure 3.10). To take up gib, tighten gib adjusting screw slightly and repeat until a slight drag is felt when moving the table by hand.

  • Page 56: Adjustment Of The Knee Gib

    ADJUSTMENT OF THE KNEE GIB Remove the chip wiper and adjust screw until smooth movement is attained (see Figure 3.12). - NOTE - Loose gibs will cause loss of machine accuracy. Chip Wiper Guard Knee Gib Adjusting Screw Backing Felt TP5331 Figure 3.12 - Knee Gib Adjustment M-450A...

  • Page 57: Backlash Adjustment

    TABLE SCREW BACKLASH ADJUSTMENT 1. Crank the table to the lift. 2. Withdraw “W”, Figure 3.13, half a turn. 3. Tighten screw “X” while slowly turning handle “Y” until minimum backlash is obtained over entire travel. 4. Finally, lock screw “W” on to “X”. 5.

  • Page 58: Cross Screw Assembly

    CROSS SCREW ASSEMBLY BACKLASH ADJUSTMENT 1. Crank the saddle to mid position 2. Remove four socket head cap screws securing bracket “D”, Figure 3.14, to knee. 3. Pull the saddle forward to expose screws “A” and “B” through hole in front of knee. 4.

  • Page 59: E-Head

    E-HEAD - NOTE - Add a few drops of Waylube #1180 oil or equivalent into oil cup “E”, Figure 3.15, before operating unit CHANGING THE GEAR CASE OIL Drain and refill the gear case with ½ pint of Mobil 600W oil or equivalent after first two months of normal service and twice yearly thereafter.

  • Page 60: Removing The Motor

    REMOVING THE MOTOR 1. Loosen two hex nuts “H”, Figure 3.17, on ei- ther side of belt housing. 2. Remove motor. TP5336 Figure 3.17 - E-Head Motor Removal CHANGING SPEED 1. To change speed, loosen the two hex nuts “I”, Figure 3.18, and move motor forward. 2.

  • Page 61: Removing The Reduction Drive Unit Or Ram

    REMOVING THE REDUCTION DRIVE UNIT OR RAM 1. Loosen hex nuts “I”, and remove motor. 2. Remove vee belt pulley “K”, Figure 3.19. 3. Remove two screws “L”, Figure 3.19, from air vent cover “M” and bring the top end of the connecting rod into view 4.
  • Page 62 - NOTES - 3-14 M-450A...

  • Page 63: Chapter 4 - Parts Listings

    CHAPTER 4 - PARTS LISTINGS 2J-HEAD TOP HOUSING TP5340 Figure 4.1 - 2J-Head Assembly M-450A Revised: April 20, 2010...
  • Page 64 2J-HEAD TOP HOUSING Item Part Number Description BP 11011033 Screw, Socket Hd Cap, .250”-20 x .750” Lg BP 12180094 Cap, Top Bearing BP 11181977 Washer, Wave Spring BP 11180252 Bearing, Ball, Fafnir #9107 NNP BP 11180848 Ring, Snap, #5100-137 BP 11011069 Screw, Socket Hd Cap, .312”-18 x 6.00”...
  • Page 65 Item Part Number Description BP 11182122 Key, Plastic BP 11011707 Nut, Hex Jam, .250”-20 BP 12180084 BP 12180107 Pin, Taper, #4 x 1.00” 53** BP 12180052 Base, Belt Housing (see BP 12183923) BP 12180088 Cover, Motor Pulley BP 11011552 Screw, Drive, Type U, #0 x .250” BP 11182893 Nameplate, Hi-Low Range BP 11182894...

  • Page 66: Back Gear

    2J-HEAD BACK GEAR TP5341 Figure 4.2 - 2J-Head Back Gear Assembly M-450A Revised: April 20, 2010...
  • Page 67 2J-HEAD BACK GEAR Item Part Number Description BP 11011710 Nut, Hex, .312” BP 11180133 Dial, Spindle Speed BP 11183646 Bushing, Bronze, .502” x .628” x 5.00” BP 11011380 Screw, Full Dog Socket Hd Set, .250”-20 x .500” BP 12180055 Housing, Speed Changer BP 12182003 Block, Plastic Bearing BP 11011031...
  • Page 68 Item Part Number Description BP 11182071 Spring, Compression, .375” OD x .3.00” Lg BP 11181794 Locknut, Bearing, #–08 57*** BP 12183924 Sleeve, Bearing BP 11181977 Washer, Wave Spring BP 12180067 Pinion, Bull Gear Shift BP 12180161 Plate, Hi-Low Detent BP 11181732 Nut, Hex, .375”-16 BP 11151913 Lockwasher, .375”...

  • Page 69: J-Head Top Housing

    J-HEAD TOP HOUSING TP5342A Figure 4.3 - J-Head Top Housing Assembly M-450A Revised: April 20, 2010...
  • Page 70 J-HEAD TOP HOUSING Item Part Number Description BP 12193502 Assembly, Drawbar BP 12180093 Washer, Drawbar BP 12190126 Locknut, Upper Bearing BP 12190125 Locknut, Bearing Sleeve BP 11190232 Bearing, #RM207 KDD-DB BP 12193506 Spacer Set, Bearing BP 11651199 Screw, Button Hd Cap, #10-32 x .500” BP 11192032 Spring, Compression BP 11011255...
  • Page 71 Item Part Number Description BP 12143452 Assembly, Gear Housing Cover (see BP 12193452) BP 12190053 Cover, Gear Housing BP 11011445 Screw, Round Hd Machine, #10-24 x .375” Lg BP 11195720 Wick, .125” OD (Common Pipe Cleaner) BP 12190120 Tube, Oiler BP 12190121 Plug, Oil BP 11193105...

  • Page 72: 2J- And J-Head Lower Housing

    2J- AND J-HEAD LOWER HOUSING TP5343 Figure 4.4 - 2J- and J-Head Lower Housing Assembly 4-10 M-450A Revised: April 20, 2010...
  • Page 73 2J- AND J-HEAD LOWER HOUSING Item Part Number Description BP 11011445 Screw, Round Hd Machine, #10-24 x .375” Lg BP 12190163 Washer, Bevel Pinion BP 12190203 Gear, Feed Bevel Pinion BP 12190164 Sleeve, Feed Worm Gear Shaft BP 11192303 Bushing, Worm Cradle BP 11011287 Screw, Stainless Steel, .250”-20 x .250”...
  • Page 74 Item Part Number Description BP 12193435 Assembly, Bevel Feed Gear BP 11183646 Bushing, Bronze, .502” x .628” x 5.00” BP 12193432 Gear, Feed Reverse Bevel BP 12190153 Clutch, Feed Reverse BP 11011547 Lock, Screw, Stainless Steel, .312”-18 x .156” BP 11011375 Screw, Stainless Steel, .312”-18 x .312”...
  • Page 75 Item Part Number Description BP 11010513 Pin, Roll, .125” x .437” BP 11192053 Spring, Compression BP 12190091 Plunger, Trip BP 12190092 Bushing, Feed Trip Plunger BP 12190090 Bushing, Trip Plunger BP 12190089 Plunger, Feed Trip BP 12193519 Assembly, Handwheel BP 12190191 Spindle BP 11190081 Skirt, Quill...
  • Page 76 Item Part Number Description BP 12190079 Hub, Quill Pinion 177*** BP 12190066 Cover, Spring 178*** BP 11192020 Spring, Clock 179*** BP 28007150 Pin, Outside Clock Spring BP 28007064 Pinion, Quill (see BP 12190108) BP 12190085 Lever, Reverse Trip Ball BP 12190086 Plunger, Feed Reverse Trip BP 12190087 Screw, Reverse Trip Ball Lever...

  • Page 77: Basic Machine

    BASIC MACHINE TP5344 Figure 4.5 - Basic Machine Assembly M-450A 4-15 Revised: April 20, 2010...
  • Page 78 BASIC MACHINE Item Part Number Description BP 12190178 Gear, Quill Housing Adj Tilting (see BP 12193500) BP 12069013 Assembly, Ram Adapter (see BP 12060129) BP 11060603 Scale, Adapter BP 11060892 Ring, External Retaining BP 11062206 Worm, Vertical Adjusting BP 12060130 Shaft, Vertical Adjusting Worm BP 12060138 Key, Sq, .187”...
  • Page 79 Item Part Number Description BP 12060206 Knee, without Chrome BP 12060493 Knee, with Chrome BP 12069999 Pin, Head Rotation Stop BP 11770252 Screw, Low Hd BP 12060148 Shaft, Knee Lock (see BP 12061230) BP 11010409 Pin, Taper, #1 x 1.00” BP 12061230 Hub, Lock Shaft BP 12060089...
  • Page 80 Item Part Number Description BP 11060602 Scale, Ram BP 11980426 Screw, Drive, Type U, #4 x .312” BP 11060601 Turret, Scale BP 11989426 Screw, Drive BP 11010200BBH Nameplate, Warning BP 11980426 Screw, Drive, Type U, #4 x .312” 4-18 M-450A Revised: April 20, 2010...

  • Page 81: Lead Screw Assembly

    LEAD SCREW ASSEMBLY TP5345 Figure 4.6 - Lead Screw Assembly M-450A 4-19 Revised: April 20, 2010...
  • Page 82 LEAD SCREW ASSEMBLY Item Part Number Description 5A 0001466 C Nut, Hex Jam, .500”-20 BP 12060271 Handle, Ball Crank BP 12150780 Assembly, Ball Crank, Quick Release BP 12060078 Nut, Dial Lock, Knurled BP 12060214 Dial, 200-Graduation Chrome, X- and Y-Axis Inch BP 12060084 Holder, Dial, Standard Handle Size BP 12630301...

  • Page 83: Flood Coolant

    FLOOD COOLANT TP5347 Figure 4.7 - Flood Coolant Assembly Item Part Number Description BP 11713642 Tank, Pump and Motor BP 11715470 Tubing, Coolant Pressure Hose, Vinyl, .50”Æ x .625” 10 ft BP 11565476 Valve, Check BP 12561010 Block, Manifold BP 11565470 Tubing, Drain Hose, Vinyl, .750”...

  • Page 84: Lubrication System

    LUBRICATION SYSTEM TP5348A Figure 4.8 - Lubrication System Assembly 4-22 M-450A Revised: April 20, 2010...
  • Page 85 LUBRICATION SYSTEM Item Part Number Description BP 11413210 Unit, Metering, Bijur #B-2495 BP 11413211 Unit, Metering, #FJB-1, B-2496 BP 11413220 Bushing, Compression, Bijur #1371 BP 11413221 Sleeve, Compression, Bijur #B-8272 BP 11413224 Tubing, Brass, .156” BP 11413225 Tubing, Nylon, .156” BP 11413222 Connector, 90°...

  • Page 86: Power Feed Y-Axis (Old Style)

    POWER FEED Y-AXIS (Old Style) TP5349A Figure 4.9 - Power Feed Y-Axis Assembly 4-24 M-450A Revised: April 20, 2010...
  • Page 87 POWER FEED Y-AXIS (Old Style) Item Part Number Description BP 11010507 Pin, Roll, .093” x .625” Lg BP 28001075 Pin, Fork BP 12630071 Fork, Stop Rod BP 28300093 Lockwasher BP 28002018 Lever, Polished Control, BP 11011268 Screw, Stainless Steel, Cup BP 11632152 Knob, Red Bakelite, .375”...
  • Page 88 Item Part Number Description BP 28300160 Screw, Socket Hd Cap, .250”-UNC x .750” BP 28300379 Washer, .125” x 1.00” x .125” BP 28300349 Nut, Hex Jam BP 11630158 Assembly, Handle, Power Feed BP 11630011 Crank, Handle Bush BP 28005069 Locknut, Dial BP 12060214 Dial, 200-Graduation BP 28006222...
  • Page 89 Item Part Number Description BP 11632618 Potentiometer, 500W, Log Taper BP 11632153 Knob, Black BP 28006280 Gasket, Control Box BP 28006004 Cover, Control Box BP 28006281 Plate, Control Box Scale 0300208 Screw, Button Hd Cap, #8-32 x .500” BP 12630033 Rod, Stop BP 11630224 Handle, Ball...

  • Page 90: Power Feed Y-Axis Control Box (Old Style)

    Plate, Control Box Back Cover BP 11630032 Gasket, Cover BP 11011420 Screw, Round Hd Machine, #8-32 x .250” BP 11632568 Board, PC, Series I Power Feed BP 11630417 Board, KB (for Models after 1989) BP 31501502 Connector, Cable Grip, .375”Æ BP 11632607...

  • Page 91: Power Feed Y-Axis (New Style)

    POWER FEED Y-AXIS (New Style) TI5646 Figure 4.11 - Power Feed Y Axis Housing with Internal Components (View 1) M-450A 4-29 Revised: April 20, 2010...
  • Page 92 POWER FEED Y-AXIS (New Style) TI5647 Figure 4.12 - Power Feed Y Axis Housing with Internal Components (View 2) 4-30 M-450A Revised: April 20, 2010...
  • Page 93 POWER FEED Y-AXIS (New Style) TI5648 Figure 4.13 - Power Feed Y Axis Lead Screw Components M-450A 4-31 Revised: April 20, 2010...

  • Page 94: Power Feed Y-Axis Control Box (New Style)

    POWER FEED Y-AXIS CONTROL BOX (New Style) TI5649 Figure 4.14 - Power Feed Y-Axis Control Box 4-32 M-450A Revised: April 20, 2010...
  • Page 95 POWER FEED Y-AXIS (New Style) Item Part Number Description BP 11011265 Set Screw BP 12632304 Stop Collar BP 12630033002 Stop Rod BP 12630071 Fork BP 11011011 Screw BP 11630426 Clevis Pin BP 11632152 Knob BP 11630890 Retaining Ring BP 12630138002 Lever BP 12636618 Shaft...
  • Page 96 Item Part Number Description BP 11630261 Bearing BP 12150289 Power Feed Dial Holder BP 12630325 Bearing Cap BP 11011010 Screw BP 12060214 Dial BP 12060078 Locknut BP 12150780 Ballcrank Handle Assy BP 12150108 Washer BP 11011033 Screw BP 12630015 Shaft BP 11013089 Woodruff Key #11 BP 11013078...

  • Page 97: 6F Power Feed X-Axis

    6F POWER FEED X-AXIS TP5352 Figure 4.15 - 6F Power Feed X-Axis Assembly M-450A 4-35 Revised: April 20, 2010...
  • Page 98 6F POWER FEED X-AXIS Item Part Number Description BP 11430097 Clamp, Stop Rod BP 12060300 Bracket, Stop, Power Feed BP 12632304 Collar, Stop BP 11010507 Pin, Roll, .093” x .625” Lg BP 11011265 Screw, Stainless Steel, .250”-20 x .250” Lg BP 12630079 Rod, Table Stop, 42”...
  • Page 99 Item Part Number Description BP 12630167 Holder, Dial BP 12060078 Nut, Dial Lock, Knurled BP 12060214 Dial, 200-Graduation BP 11011011 Screw, Socket Hd Cap, #10-24 x .625” Lg BP 12630325 Cap, Take-Up BP 11630261 Bearing, Single Row, Loose Fit BP 11630814 Ring, Retaining, #5100-78 BP 11632074 Spring, Clutch...
  • Page 100 Item Part Number Description BP 11636006 Plate, Micro Switch Mount BP 12630052 Box, Control 0100640 Screw, Socket Hd Cap, .250”-20 x 2.500” BP 11011190 Screw, Button Hd Cap, #8-32 x .250” BP 11632576 Cover, Control Box BP 11632506 Boot, Insul PB/Switch BP 11632620 Pushbutton, SPST BP 11632618...
  • Page 101 8F POWER FEED X-AXIS TP5353 Figure 4.16 - 8F Power Feed X-Axis Assembly M-450A 4-39 Revised: April 20, 2010...
  • Page 102 8F POWER FEED X-AXIS TP5354 Figure 4.17 - 8F Power Feed X-Axis Assembly 4-40 M-450A Revised: April 20, 2010...
  • Page 103 8F POWER FEED X-AXIS Item Part Number Description BP 11011720 Nut, Hex, .375”-16 BP 12060122 Washer, Tee Bolt BP 11061602 Bolt, Square Hd, .375”-16 x 1.375” BP 12430097 Guide, Stop Rod BP 11010507 Pin, Roll, .093” x .625” Lg BP 11011265 Screw, Stainless Steel, .250”-20 x .250”...
  • Page 104 Item Part Number Description BP 11632216 Gear, Drive Shaft, Standard Torque BP 11632218 Gear, Drive Shaft, High Torque BP 12632051 Hub, Gear 0100620 Screw, Socket Hd Cap, .250”-20 x 1.250” BP 12630091 Washer, Thrust BP 11013078 Key, Woodruff #7 BP 11013089 Key, Woodruff #11 BP 12630015 Shaft, Drive, Power Feed...
  • Page 105 8F POWER FEED X-AXIS TP5355 Figure 4.18 - 8F Power Feed X-Axis Control Assembly, Exploded View M-450A 4-43 Revised: April 20, 2010...
  • Page 106 8F POWER FEED X-AXIS Item Part Number Description BP 11011031 Screw, Socket Hd Cap, .250”-20 x .625” BP 11632659 Switch, Toggle 2PST BP 11632599 Nut, Hex BP 11632628 Boot, Toggle Switch Insulator BP 11632620 Pushbutton, 1PST BP 11632506 Boot, Insul PB/Switch BP 11632593 Light, Pilot BP 11632607...
  • Page 107 POWER FEED X-AXIS TP5356 Figure 4.19 - Power Feed X-Axis Control Assembly, Front View Item Part Number Description 0300104 Screw, Button Hd Cap, #6-32 x .250” BP 11632618 Potentiometer, 500W, Log Taper BP 11630445 Potentiometer, 8F Power Feed BP 11632153 Knob, Black BP 11632607 Fuseholder, Panel Mount...

  • Page 108: Replacement Motor Assemblies Available

    REPLACEMENT MOTOR ASSEMBLIES AVAILABLE Motor Assembly J-Head 1 HP Unified without NFPA, BP 12190250 Part Number Description BP 11011595 Screw, Washer Hd Machine, #10-32 x .375” BP 11012759 Marker, 208 Volts BP 11012760 Marker, 230 Volts BP 11012761 Marker, 380 Volts BP 11012762 Marker, 460 Volts BP 11012772...

  • Page 109: Motor Assembly 2J-Head 2 Hp 575 Volts Without Nfpa

    Motor Assembly 2J-Head 2 HP 575 Volts without NFPA, BP 12550020 Part Number Description BP 11010514 Pin, Roll, .125” x .500” BP 11012763 Marker, 575 Volts BP 11150843 Ring, Retaining, #5100-118 BP 11182556 Set, Cord, 14/4 600 Volts BP 11182557 Assembly, Cable, 600 Volts BP 11182655 Switch, Drum...

  • Page 110: J Milling Head - Spare Parts Kit

    J Milling Head – Spare Parts Part Number Description BP 11182120 Belt, Varispeed BP 11182106 Belt, Timing BP 12193477 Shoe, Brake BP 11182081 Spring, Brake BP 12193437 Assembly, Clockspring and Cover BP 12180117 Lubricant, Gear BP 11190238 Bearing, Spindle, Pair BP 11190237 Bearing, Spindle BP 11192403...

  • Page 111: Series I Standard Machine - Spare Parts Kit

    Series I Standard Machine – Spare Parts Part Number Description BP 11062405 Wiper, Felt BP 11062406 Wiper, Felt BP 12060631 Nut, Lead Screw Cross Feed Inch Matched BP 12060630 Nut, Lead Screw Feed, Inch Matched, Lg BP 12060123 Plate, Wiper, Knee Lead Screws for Manually Operated Machines (without Keys) Note: Keys for the Following Lead Screws are BP 11013078, Woodruff #7.

  • Page 112: J- And 2J-Head, Metric Conversion Kit

    METRIC CONVERSION KITS BP 2184000 – J- and 2J-Head, Metric Conversion Kit Part Number Description BP 11195307 Scale BP 12191013 Assembly, Stop BP 2064001 – Metric Conversion Kits Hand Feed Machines with 36” Tables Part Number Description BP 12060175 Screw, Lead, Table BP 12060183 Screw, Lead, Elevating BP 12060730...

  • Page 113: 6F Power Feed Field Conversion Kits For Machines Without Nfpa

    BP 2064003 – Metric Conversion Kits Hand Feed Machines with 48” Tables Part Number Description BP 12060179 Screw, Lead BP 12060183 Screw, Lead, Elevating BP 12060730 Nut, Table Feed BP 12060731 Nut, Saddle Feed BP 12060170 Nut, Elevating BP 12069016 Dial, Table and Saddle BP 12069015 Dial, Elevating Screw...
  • Page 114 - NOTES - 4-52 M-450A...

  • Page 115: Chapter 5 - Specifications

    CHAPTER 5 - SPECIFICATIONS MACHINE PRINCIPLE DIMENSIONS TP5264 Figure 5.1 - Machine Principle Dimensions TABLE TRAVEL TABLE LENGTH 30” (762mm) 42” (1067mm) 36” (914mm) 48” (1219mm) 82” (2083) 51” (1295) 8.750” (222) 2.500” (64) 6.750” (171) 82” (2083) 63” (1600) 20.750”...

  • Page 116: Floor Plan Installation Layout

    FLOOR PLAN INSTALLATION LAYOUT TP5265 Figure 5.2 - Machine Specifications Principle Dimensions ‘A’ DIMENSION TABLE SIZE PLAIN MACHINE POWER FEED 42” (1067mm) 87” (2210mm) 91” (2311mm) 5-3/4” 48” (1219mm) 93” (2362mm) 97” (2464mm) (146mm) 5/8”Æ (16mm) TP52383 Figure 5.3 - Machine Dimension - Hold-Down Bolt M-450A...
  • Page 117 TP5266 TP5267 Figure 5.4 - Machine Specifications Figure 5.5 - Machine Specifications Side View Front View Table Size 42” x 9” 1067mm x 229mm Table Travel Hand Only 30” 762mm Table Travel with Power Feed 27.500” 699mm Saddle Travel 12” 305mm Vertical Travel 16”...

  • Page 118: Machine Specifications

    MACHINE SPECIFICATIONS RANGE Table Travel (X-Axis) 30” (762mm) 36” (914mm) (42” Table) (48” Table) Saddle Travel (Y-Axis) 12” (305mm) Quill Travel 5” (127mm) Knee Travel (Z-Axis Manual) 16” (406mm) Ram Travel 12” (305mm) Throat Distance (Minimum) 6.75” (171mm) (Maximum) 18.75” (476mm) Table to Spindle Nose Gage Line (Minimum) 2.25”...

  • Page 119: Head

    HEAD MILLING SPECIFICATIONS *No longer available/part orders only MODEL M-HEAD J-HEAD J-HEAD 2J-HEAD 2J-HEAD HI-SPEED PRE-1977 POST-1977 Power .5 HP 1.0 HP 1.5 HP 1.5 HP 2.0 HP Motor RPM 1200 RPM 1800 RPM 3600 RPM 1800 RPM 1800 RPM Speed Ranges –RPM 6 Steps 8 Steps...

  • Page 120: 2J-Head

    2J-HEAD GENERAL SPEED RECOMMENDATIONS FEET PER MINUTE ROUGH ROUGH AND LIGHT AND MATERIAL TO BE CUT FINISH FINISH CUT Cast Iron – Soft (Under 150 Brinnell) 80 – 90 Cast Iron – Med (150-200 Brinnell) 60 – 70 Cast Iron – Hard (Over 200 Brinnell) 50 –...
  • Page 121 TP5268 Figure 5.6 - 2J-Head Specifications Spindle Taper Spindle Speeds – RPM 60-4200 60-4200 Motor *2 HP 1.5 kw Quill Travel 5” 127mm Power Feed of Quill .0015” .04mm per Rev of Spindle (3 Rates) .003” .08mm .006” .15mm Collet Capacity .125”...

  • Page 122: J-Head

    J-HEAD TP5269 Figure 5.7 - J-Head Specifications Spindle Taper Spindle Speeds – RPM Low Range High Range 80, 135, 210, 325 660, 1115, 1750, 2720 Motor 1 HP .750 kw Quill Travel 5” 127mm Power Feed of Quill .0015” .05mm per Rev of Spindle (3 Rates) .003”...

  • Page 123: E-Head

    E-HEAD TP5270 Figure 5.8 - E-Head Specifications Oscillation Rate 60, 85, 120 (Stroke per Minute) 170, 245, 350 Motor 1/3 HP .250 kw Stroke Adjustment .125” – 4” 3 - 100mm Tool Capacity Horizontally Mounted .375” 10mm Vertically Mounted .625” 16mm Weight 112 lb...

  • Page 124: 6F Power Feed

    6F POWER FEED SCHEMATIC TP5271 Figure 5.9 - 6F Power Feed Schematic 5-10 M-450A...

  • Page 125: 6F Power Feed Circuit Board

    6F POWER FEED CIRCUIT BOARD TP5272 Figure 5.10 - 6F Power Feed Circuit Schematic M-450A 5-11...

  • Page 126: 8F Power Feed

    8F POWER FEED SCHEMATIC TP5273 Figure 5.11 - 8F Power Feed Schematic 5-12 M-450A...

  • Page 127: 8F Power Feed Circuit Board

    8F POWER FEED CIRCUIT BOARD TP5274 Figure 5.12 - 8F Power Feed Circuit Board Schematic M-450A 5-13...

  • Page 128: 8F Power Feed Schematic

    8F POWER FEED SCHEMATIC TP5275 Figure 5.13 - 8F Power Feed Schematic 5-14 M-450A...

  • Page 129: Parts

    PARTS 8F POWER FEED SCHEMATIC Circuit Ref Value/Rating Mfr Type Function .22ufd – 100V Capacitor C2, 3, 8 .1ufd – 100V Capacitor 100ufd – 35V Capacitor C5, 6 .1ufd – 250V Capacitor .0033ufd – 100V Capacitor C10, 11 4.7ufd – 25V Capacitor C12, 13, 15 .01ufd –...

  • Page 130: 8F Power Feed Circuit Board

    8F POWER FEED CIRCUIT BOARD TP5276 Figure 5.14 - 8F Power Feed Circuit Board Schematic 5-16 M-450A...

  • Page 131: 8F Power Feed Circuit Board

    8F POWER FEED CIRCUIT BOARD Circuit Ref Value/Rating Mfr Type Function C1, 3 10.0ufd - 35V Electrolytic Capacitor 0.47ufd - 50V Electrolytic Capacitor 0.022ufd - 250Vac /630Vdc Mylar Capacitor Conn. 1 CE156F20-4 End Connector D1, 2, 3 1A - 600V 1N4005GP Diode D4, 5...
  • Page 132 - NOTES - 5-18 M-450A...
  • Page 133 - NOTES - M-450A 5-19...

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