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MILLRITE

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MAINTENANCE INSTRUCTIONS AND PARTS LIST

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MILL SAFETY INSTRUCTIONS 1. GROUNDING THE MILL: Make certain that the machine frame is electrically grounded and that a grounding lead is included in the incoming electrical service. In caseswhere a cord and plug are used, make certain that the grounding lug connects to a suitable ground. Follow the grounding procedure indicated by the National Electric Code. EYE SAFETY: Wear an approved safety face shield, goggles or glassesto protect eyes when operating the Mill. PERSONAL PROTECTION: Before operating the machine, remove tie, rings, watch and other jewelry and roll up sleevesabove the elbow. Remove all outer loose clothing and confine long hair. Protective type foot wear should be worn. Hearing protectors should be used where noise exceedsthe level of exposure allowed in Section t9t0.95 of the OSHA regulations. DO NOT WEAR GLOVES. WORK AREA: Keep the floor around the machine clean and free of tools, tooling, stock, chips and other foriegn material, and oil, greaseor coolant to minimize the danger of tripping or slipping. Be sure the machine is free of chips, tools, and everything else not required for the task to be performed. Powermatic Burke recommends the use of anti-skid floor strips on the floor area where the operator normally stands and that each machine's work area be marked off. Make certain the work area is well lighted and ventilated. Provide for adequate work space around the machine. DISCONNECT Machine electrics before any maintenance is performed. All maintenance and repair work should be performed only by someone qualified to do so. REPLACEMENT PARTS: Use only Powermatic Burke or factory authorized replacement parts and accessories;otherwise, the warranty and guarantee will be null and void. HAND SAFETY: Keep hands away from the cutting tool and work area when the machine is under power. MACHINE ADJUSTMENTS: Make all machine adjustments with power off except speedon a variable speedmodel. AVOID ACCIDENTAL STARTING: Make certain the motor switch is in the off position before connecting power to the machine. LIGHTING: Be sure the machine area is well lighted and ventilated. Follow the requirements of the OSHA regulations.

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SPECIFICATIONS Spindle: Taper. Speed' (A) Step-PulleyModel (RPM)

R-8 (standard),No. 9 B & S, No. 2 Morse,No. 3 Morse, No. 30 NS

(1) with l/2 HP Gearmoror (2) With 3/4HP Gearmoror Or... Or... Or... (3) with1HP90oRPMMotor..... (4) WithlHP1200RPMMotor(standard).... (5) With I HP 1800RPMMotor (B) Variable-Speed Model (RPMRange) (1) With 1 HP 900 RPMMotor (standard) (2) With 1 HP 1200RPMMotor. . . . . (3) With 1 HP 1800RPMMotor Table: Sizeof workingsurface . . . . 7" x 27"
T-Slots,Number and size. Dials Graduation: (A) Inch (standard) (B) Metric. (C) Inch/Metric . Range: Longitudinal table travel: (A) 7" x 27" Table (standard) (B) 8" x 32" Table.

. . z s,r3o,zrs,3so,6go,10g0 . . . 6S,tOS,lgO,ZgO,575,g60 ....130,215,360,580,1150,1720 ....195,325,545,820,1730,2590 ...260,435,225,1160,2300,3440 ...19o,32o,530,850,1680,2s20 ...26O,435,725,1t60,23O0,3440 .390,660,995,1760,3490,5220 . .2TS to 2250 350 to 3000 500 to 4500 (177.8mm 685.8mm)(standard) x
8" x 32" (2O3.2mmx 812.8mm)

8" x 36" (203.2mm 914.4mm) x


Three, lL/16" (17.45mm) Wide, 2-l/8" (53.98mm) Betweenslots . ..001" (.03mm) ... ..001"/(.02mm) . . 16" (406.4mm) (manual) (standard) . . 14" (355.6mm) (powerfeed) . . . .21" (533.4mm) (manual)

(C)'b;"* :::::::::::::::::::.::::::.:::::.:::::::.:?'.' l?;''i"ur.. .'i.3t#?I$,Xh'ji . . 23" (584.2mm) (powerfeed)


Cross.Table travel: (A) With 8" Knee (standard) (B) With 13" Knee Vertical, knee travel: (A) Without coolant tank (standard) . . (B) With coolant tank. . Quill Travel: Distance, Spindle Nose (R-8) To Table Top: (A) With plain overarm (standard) . . . . (B) With compound overarm Power-feedOptions (feed rates) 8" (203.2mm) . . 13" (330.2mm) . . .15" (381mm) . . . 11" (279.4mm\

.t-314" (44.5mm) (minimum) . . . .2-l/4" (57.2mm) (minimum) . Traversespeed40IPM (16.93mm/SEC) Feed speed3/4lPM (.3mm/SEC) to 25IPM (10.58mm/SEC) Riser block option between column and turret .5" (127mm) Spindle to column face: (A) With plain overarm (standard) . . . . . . 4" (l0Zmm) minimum,16-l/2" (419mm) maximum (B) with compound overarm 6-112" (165mm) minimum, 17" (43zmm) maximum Range: Max. allowable size or weight of cutting tool and assembly. 1" end mill (25.4mm) Max. recommended weight of work piece and fixture. . . .375 Lbs. (170 Kg.) (Refer to the American National Standard - Safety requirements for the construction, care, and use of drilling, milling and boring machine.)

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In order to become proficient in the use of a Millrite, the operator should first learn the location and function of all controls. He should then operate each control, except the variable speed handwheel, with the power off in order to get the feel of how it operates. This is a general overall view of the Millrite showing the location and namesof the rnajor components and controls.

DRUM TYPE REVERSING SWITCH SPINDLE LOCK

CHART

MOTORGUARD HEAD LOCKINGNUTS NDLE BRAKE

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TURRETT

QUILL FEED HANDWHEEL

UILL FEED DIAL


DEFTHOF FEED SCALE

QUILL LOCK

QUILL COLLETS TRAY

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COLUI'rN--t/ TABLE FEED DIAL TABLE FEED.HANDLE SADDLEGIB LOCK KNEE GIB LOCK TABLE GIB LOC KNEE GIB LOCK ) \-

TABLE

WERFEED UNIT

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CROSSFEED DIAL CROSSFEED HANDWHEET

VERTICAL FEED DIAL VERTICAT FEED HANDWHEEL

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CRANEI TON MIN.


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FIG 5 LIFTINGTHE MACHINE

PROPERLIFTING SLING

TIGHTENRAM LOCKING

BOLTSBEFORE LIFTING

TIGHTEN BOLTS 4 BEFORE LIFTING MOVE TABLE AGAINST COLUMN

INSTALLED GROSS WEIGIITOF MACI-.{INE I 600LBS

UNCRATING: The Millrite is an accurate, precision built machine tool. It should be -on carefullv uncrated and inspected. Be sure that all items listed the packing slip are contain.d i;1h; ;;;;;. iid;rr any shortages immediately-. In the event of shopping d3rnage pliase hake a notation on rhe bill of lading, have the delivering carrier sign to this effect, and notily powirmatic Burke. STANDARD EQUIPMENT CARTON CONTAINS THE FOLLOWING ITEMS: 1 - Draw Bar 1 - Crank Handle requirements for the construction, care and use of Milling Machine. | - lafeE I Installation and Maintenance Manuals 1 - Operating Instructions Manual I - Warranty Card Carefully read the Operating Instruction Manual before operating machine. Fill out the Warrantee card and return to Powermatic Houdaille, Inc. HANDLES: When crating, the two table handles are taped to table end brackets. The head finequill feed handwheel is turned to face the machine. This handwheel should be reversedu"J tn. t"n-t. t uiaGr rr,o.rra be assembledbefore operating.. Slide table handles and the head fine quill feed handwheel over the key, located in the head screw, table screw and cross travel screw. Tightei set screws located in the handles and handwheel. INSTALLATION OF MILL: The machine should remain on the skid until moved to its assigned working area.Position the head in its normal uprtght position. CAUTION - refer to article "pOSITIO1\|ING HEAD" before attemPting this maneuver. RoiatJ thi motor mounting bracket to the back of the machine. Tighten motor mount bolt and the head locking nuts. Position the overarm as shown in figure 4 atrJ tilnt." ou..arm locking i1 liftingtf,emactine lut!.Remove the four bolts-holding the machine ro the skid. Use from the skid. If a overhead crane is used, be sule tha capacity is atleast 2000 pounds and lift ""r? the mill by placing a sling lnder the ram as illustrated in.Fig. 4. Place thl machine on a sblid tevel floor, preferably co.ncrete'in a dry well lighted area. When placing machine on a concrere foundation, it is advisJble to use a little grout (th-in mortar) to take care oT any unevnness in the concrete as well as to proviJe a solid foundation at all Points..When setting machini on a floor that has surface irregularitier, ,lii-, should be used to correct this condition to the greatest extent possible. NOTE: It is recommended that the machine be laggedto the floor. See Fig. 5 for installation layoui. LEVELING MACHINE ' Set machine by leveling the work table lengthwise and crosswisewith a precision level. CLEANING: Thoroughly clean -protective. coating from machine with suitable cleaning solution. WARNING: It is not recommended that gasoline or atry other highly inflammable solvent be used. DO NOT move the table, saddle,.knee or any moveable part until all wiyjhave been well cleaned and lubricated. (see lubrication page ) Then,-by-hand, moveiable, saddle krr.. to limit stop in one direction. Clean . "nd and.lubricate expose,dways and ihen move each unit to rhe opposite limit stop and similarly clean and lubricate the exposed ways. Loosen bolts to unlock the ram, und -ou. it forward and backward to the full length in order to clean and lubricate with SAE NO. 10 oil. SAFEGUARDING THE HAZARD AREA The safeguarding-of the" hazard area requires knowledge of the workpiece, its fixture or clamping method, the. operation to be performed, the cutter, if coolant iJto be used and in wirat form, the directionl q.rantity and velocity of the chips created and many other factors which determine the kind and nature oi t'he safeguarding method which will best help to privent injuries. The American National StandardsInstitute standard Bll.8-lg-74 section 5, a copy of which is supplied with this mill, defines responsibiliq' for and the various methods of safeguarding'the htzard area. Review its recommendations and determine what method best fits the situati6n on io,r, operation and install it before using the mill for that operation. If your comPany does not Possess the technical capibility to evaluate what is needed to protect and train operators' there are many capable firms available in most metropolitan areasto perform this service.

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CONNECTING PowER SUPPLY: To connect the machine to the plant power supply have a qualified electrician proceed as followe: required machine voltage and phase against power zupply to insure they are the same. 1. 9*k 2. Connect machine wiring to power supply mfing su.e conn"ction is in lompliance with local electrical codes. 3. Check for correct spindle rotation. (Forward position . . . . Counterclockwise) LUBRICATION: Do not operate machine until properly lubricated. A number of Alemite fittings are located in different positions around the machin",-* .ho"* in Fig. 4. Using a greaEe gun filled with Sohio waylube No. 50 or equivalent, lubricate the areas marked A. Uiing Sohio" fram XJ. 2 grease, lubricate areasmarked B. Lubricate the Timken bearings in the quill every 200 hours of operation. To accomplish this; First lower the quill until the ptlu^ q1$_is_expoeed. Then remove the pipe plug and pack the area with Sohio Sactram No. 2 or equivalent. DO NOT OVERFILL as this ttt"y eicessii heating in the spindle. "",rr" Specifically, the best greate to use for this purpose ie a ehot fibre, medium sponge grease, with sodium soap base. This is not- a critical requirement, however, the main concern is not to lubricate theee bearings too often or too heavily. Lightly oil the top of the table and the outside surfaces of the quill with SAE No. l0 oil, not less than once a month while the machine is in use. POSITIONING THE HEAD: The head is mounted in the swivel disc with four T-bolte and nute. l. (Standard) Model without worm/worm wheel drive: To reposition (swivel) the head, loosen three nuts and crack loose the fourth nut only enough to allow the head to move when hand force is ueed. Reposition (swivel) the head. Tighten the four nuts. CAUTION: NEVER loosen all four nuts. 2. Model with optional worm/worm wheel drive: To reposition (swivel) the head, loosen four nuts. Crank the shaft until the head reachesthe position desiied. Ti[hien the four nuts. REPOSITIONING (TILT) HEAD (ON MACHTNE WrTH OPTTONAL COMPOUND OVERARM): The compound swivel disc is locked to the overarm with two screwEon top. l. (Standard) Model without worm/worm wheel drive: To reposition (tilt) the head, crack loose the two screws only enough to allow the head to move when hand force is used. RepoEition (tilt) the head. Tighten the two Ecrewr.CAUTION: NEVER loosen both screws. 2. Model with optional worm/worm wheel drive: To reposition (tilt) the head,loosen the two rcrewg. Crank the shaft until the head reachesthe position desired. Tigirten the two Bcrew6. ATIGNMENT oF HEAD: In of precision boring or work of that nature, where it ie necessaryto 9as9 have head perfectly Equare with the table, or when the position of the head has been changed, it is absolutely neceesary to eweeP the table with an indicator to make sure the head is in a true position. "eiical Thie-is most easily accomplish"d by securing an indicator to the spindle nose to in a test bar held in the spindle. NOTE: When indicating as in figures 7 and 8, it should be noted that the table is fitted to be slightly high in front, approximately .0005".

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TO ADJUSTPRETOADOF TTMKEN BEARINGSON MITLRITE SPINDLE

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Feedout quill until plug "A" is exposed. Remove plug "A" with 5/16" Hex. key.

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Rotate spindle manually until l/4" socket set ecrew "8" in preloading nut is accessiblethrough plug hole. Loosen this aet screw with UB" Hex. key. Insert pin wrench in any of (3) 3/16" radial holes in preloading nut. Be careful not to damagethread in plug hole. Turn spindle at "C" position to right to ir/crease
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Assure proper seating of bearing races on spindle - _ by fightly tapping toiand bottoniof spindle. Rotate spindle to feel the "drag" on the bearinge. There should be no noticable drag when running predominatly at high spindle speeds. Tighten eet ecrew "8" and replace outer plug "A" in quill. Make zure that plug clears quill housing, But do not force it in too far or it might interfere with inner rotating part8.

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KNEE GIBS: To adjust the standard gtb o. the knee, back off the jam nuts on the seven gib adjusting screws. Adjust the top and bottom screws in, until a light drag is felt when raising or lowering the knee. Lock their jam nuts. Now proceed with the second screw from the top and bottom and adjust in the same as the first two screws. Then adjust the next two outside screws and finish up with the center and final screw. Be sure to relock all jam nuts as each screw is adjusted.

KNEE-TAPER GIB:
A. Loosen bottom gib screw l/4 turn. B. Raise knee, by turning vertical screw, approximately one inch. C. Tighten top gib screw until tight. D. Move knee up and down. Continue steps A,B,C, and D until movement has proper feel. SADDLE GIB: To adjust the standard saddle gib, back off all three set screws. Snug down the socket head cap screw in the gtb to that a slight drag is felt when moving the saddle. Adjust the set screws in until they are tight. Check for free motion in both directions.

SADDLE_TAPER GIB:
A. Position saddle away from the column (approximately to the end of the knee). B. Loosen the gib screw, to the rear of the saddle, l/4 turn. C. Tighten the front gib screw tight. D. Using cross feed screw move saddle away from and towards the column. E. Continue steps A,B,C, and D until movement has light drag feel. TABLE GIB: To adjust the standard table gtb it will be necessary to remove the table, saddle assembly from the knee. To accomplish this, it will be necessary to remove the saddle screw assembly. Remove the handwheel, dial and then the screw support. By removing the three socket head cap scte*. holding it in the saddle, rotate the screw until it is free from the saddle nut remove the screw assembly. Unlock the table and saddle and then remove the saddle gb by removing the four socket head cap screws holding it in the saddle. Lift the table and saddle assembly off the knee and set it on a bench or on the floor, table down. Back off all set screws. Snug all cap Ecrews. Using the table handcrank check for a slight drag. Adjust the set screws in until they are tight. Check for free motion in both directions. Lightly oil the table and saddle ways and reinstall on the knee. Mount the saddle gib and adjust it per preceeding instructions. Reinstall saddle dial bracket and screw.

TABLE_TAPER GIB:
A. Position table to the left hand side of the machine. This will aid getting to the one gib screw. B. Tighten the table gib adjusting screw, then turn table feed Ecrew. C. Repeat steps A and B until table movement has light drag feel. GOOD HOUSEKEEPING: Good housekeeping is of major importance on preventative maintenance. A clean machine will operate much longer, easier and more efficientally than a dirty one. Keep the mill clean and free of chips, by using a chip rake or brush. DO NOT USE AIR to blow chops from OR USE HANDS to remove chips from the machine. CONDITION OF ACCESSORIES: The condition of tool holders, tools, jig and fixtures, vised, dividing heads and other acceesorieeare important. Inspect these items on a regular basis. Keep them clean and coated with a film of light oil to provent rust. Inspect the tapers and diamerers of all toolgand tool holders. Remove nicks and dents which would interfer with the proper seating of the taper. In insert type tools, index or replace damaged inserts.

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OYERALL CONDITION OF MACHINE: A periodic inspection and adjustment on a regular basis of not lessthan once every 6 months for: A. Loose screwg B. Worn belts C. Worn, damaged or missing parts D. Loose gibs E. Improperly operating adjusting Ecrewsfor the knee, saddle, table and quill F. Excessivelost motion in dials G. Improper lubrication H. Loose electrical connections I. Column out of level and in twist J. Bad bearings Any problems discovered should be repaired as soon as poseible and if operator safety ir involved, the machine should be electrically locked out and red tagged until the repairs are made. REPLACE BELT-STEP PULLEY: To replace a belt on a step pulley model, looeten the two wing nuts on each side of the belt guard and swing the guard forward. Loosten the two l/2" hex nuts locking the motor bracket. Pull the motor bracket forward toward the front pulley. The belt is free to be removed from the machine and a replacement can be added. Swing the motor bracket back to teneion the belt and lock in position. Close the belt guard and lock it in position. SPEED: Lower the quill to its lowest point and lock in place. Remove the REPTACE BELT-VARIABLE head cap screws from either side of the belt guard with a l/8" Allen wrench. Using a Ecrew three button driver remoye the four self tapping screws from the lower plate on the belt guard. At the front remove the molding and plate. Remove the speed adjusting cam by unscrewing the shoulder bolt in its center with a 5116 Allen wrench. Lift the guard up and loosen and remove the four 51L6" socket head cap Bcrews attaching the front plate to the lower plate and remoye the front plate. Take hold of one side of the belt and pull out to force the belt into its bottom position in the motor pulley. Drive out the pivot pin in the yoke arm and remove the yoke arm. Slip the belt out of the spindle pulley. Loosen and remove the four Ll2" hex head mounting screws holding the motor bracket to the lower plate. Tilt the motor, motor bracket and belt guard o[ to remoye the belt. Place a new belt in the motor p"U"y and pull out td bottom it in the pulley and retrace the previous steps.

V-BILT

MOTOR BRACKET R P M P L AT E W I N GN U T HEX NUT

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REMOVING TABLE: l. Slide eyebolt and tee-slot key assenbly to the center of the table and tighten. 2. Affix crane hook to the eve bolt. Position the table approximately I inchee to the right hand eide of the saddle center line. This 3. positions the table tcrew nut approximately to the center of the table screw. 4. Remove the right hand table end bracket assembly. A. Remove crank handle by loosening the set screw. B. Remove the Woodruff key in the table ecrew. C. Loosen thumb screw in the dial and elide dial off table Bcrew. D. Remove three eocket head cap screwr holding right table bracket to the table. 5. Remove the left hand table end bracket aseembly. A. Remove crank handle by loosening the set screw. B. Remove the Woodruff key in the table screw. C. L,oosenthumb Bcrew in the dial and elide the dial off the table Bcrew. D. Loosen bearing take-up nut and remove it and the outer thrust bearing. E. Remove three socket head cap rcrews holding the left table bracket to the table. F. With the crane ilpporting the table, slide the table from the saddle. G. When placing table on work bench, place clean candboard between dovetail and work bench. H. Before reassembly, clean and lightly oil the table ways. REMOVING SADDLE: It will be necessary remove the table, saddle assembly. to A. Remove the handwheel, dial and then the screw support by removing the three socket head cap rcrews holding it in the saddle. B. Rotate the screw until it is free from the saddle nut. C. Remove the saddle screw aseemblv. D. Unlock the table and saddle and then remove the saddle gb by removing the four socket head cap Bcrewsholding it to the saddle. E. Lift the table, saddle assembly off the knee and set it on a bench. F. If the table must be removed refer to table removal instructions. REMOVING KNEE. A. l,oosen four nuts top of column and swivel turret, oyerarrn assembly approximately 90 Deg. B. Center the table to the saddle and lock in position. C. Poeition saddle towande the column, as close as possible, but be sure it clears the top of the column and then lock. D. Loosen set screw, that holds the vertical feed nut. E. Position lifting sling around each end of the table. F. Gently lift table, saddle, and knee assembly from the column. G. If a desire exiets to remove the table, eaddle assembly, this ehould be done before steps A - G. REPLACE SPINDLE WITHOUT REMOVING QUILT: l. Secure quill lock with quill in lowered position. 2. Remove motor and draw bar. 3. Take off spindle pulley, after loosening the set screw in the spindle pulley nut and unscrewing it. 4. Mark the position of the pulley sleeve for re-assembly, unscrew 3 flat head ecrews that hold it in place and take it off. 5. Remove quill nut. Note: This nut has a left hand thread. Unecrew the pipe plug in the rear of the quill. 6. 7. Take off the snap ring on top of the spindle that holds it in position. B. Tap the spindle lightly and it will drop out. 9. The new spindle is furnished with pre-adjusted and greased gearings so that to inetall it merely reversethe above prosedure. CAUTIoN: Be sure that the snap ring is replaced with the correct side up.

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REMOVE MOTOR (STEP PULLEY): Loosen two wing nuts on each side of the guand and swing the guand forward. Loosen the two ll2" hex nuts that lock the motor housing to the motor head plate and slide the motor housing forward. Remove the "V" belt and the Il2" hex nuts. Disconnect the electrical wiring and fitting from the motor conduit box. Lift the motor, pulley and motor housing assembly from the motor plate. Remove the pulley retaining snap ring and loosen the set screw located in the pulley. Remove the housing and pulley by loosening the bolts in the motor adapter plate and sliding the pulley and housing from the motor shaft. Remove motor adapter plate. REMOVE MOTOR (VARIABLE SPEED): Lower the quill to its lowest point and lock in place. Remove the three button head cap screws from both sides of the belt guard with a l/8" Allen wrench. Using a screw driver remove the four self tapping screws from the lower plate on the belt guard at the front. Remove the moulding and lower plate. Remove the speed adjusting cam by unscrewing the shoulder bolt in its center with a 5/16" Allen wrench. Lift the guard up and remoye the four 5/16" socket head cap screws attaching the front plate to the lower plate and remoye the front plate. Take hold of one side of the belt and pui out to force the belt into its bottom position in the motor pulley. Drive out the pivot pin in the yoke arm and remove the yoke arm. Slip the belt out of the spindle poll"y. it"tt ove the foui U2"-hexhead mounting screws holding the motor bracket to the lower plate, tilt the motor, motor bracket and belt guand up to remove the belt. Remove the guard, then lift the motor, pulley and motor mounting bracket assembly from the motor plate. Remove the retaining snap ring and slide pulley from the rnoto. shaft. Remove motor mounting bracket.

POWER FEBDINSTATTATION:
Remove the handle, dial, key and end cap from the right hand end of the milling machil. Tap leadscrew U4-20 thread, 3/8 deep. Rework dial per Print 4-466 Slide A-468 spacerand 4-470 bearing race on shaft. Move the table to the extreme left hand position in onder to have the leadscrew aEclose to the nut as possible. Screw the two 5/16-8 transfer screws into the outer holes that were used to support the original right hand bearing bracket. Slide the Mill Table Feed with the C-680 or C-241 adaptor in place over the A-682 bearing race and lightly tap the adaptor against the pointe of the transfer screwE marking the propei location for drilling. Remove the C-680 or C-241adaptor from the table feed and drill out two holes in the indicated places to 2U64 Dia. Attach the adaptor to the mill using the 5/16-18 x l-3/4" socket cap screws supplied. Due to the variations in the length of the Millrite leadscrew, it may be necessaryto shorten the spacer somewhat. The spacer and the bearing race should stick out about l-l/32- from the inside surface of the adaptor casting. see drawing D-r64. Modify as required.

DRM UNIT INSTALTATION: Leave bearing race on leadscrew and place feed unit on the adaptor usingthe l/4-20 x l" socketheadcap screws. DIAL AND HANDCRANKINSTALLATION:
l. After the bevel gear has been properly shimmed, the dial should be shimmed to provide .00S" spacing between the drive unit housing and the dial, Thie is important in onder io keep chips out of the drive unit. Four washers are provided for this. (Two solid and two laminated) Add A-780 sleeve and A-779 shaft exteneion. Secure with the screw provided. Slide collar to dial and secure. Add the key in the shaft extension. Install handle and secure.

2. 3. 4.

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LIMIT SWITCH INSTATTATION: (8" TABLE) l. Remove the two cap screwsholding the existing "Tee" stop piece. 2. Insert the two cylindrical standoffs into the counter bored holes in the "Tee" stop piece. 3. Put the limit switch assembly over the two standoffs and screw dorrn the complete assembly using the cap screws supplied. 4. Replace the existing adjustable table stop pieces with the pair furnished. Note: For proper operation of the limit switch assembly, the electrical stop should be engaged .4" before the mechanical stop is struck. This allows for coasting of the table when the feed is on the high speed setting. The table stop pieces should be turned until the proper spacing is provided. in each direction. CAUTION: Do not allow the stop piecesto strike the body of the limit switch assembly. 5. The limit switch cable should be held off the ways using the cable clamp enclosed. Drill and tap B-32 into the table to securethe cable clamp. LIMIT SWITCH INSTALTATION: (7" TABLE) l. Remove the adjustable stops and replace with A-465 table stop pieces as shovm on the Drawing

D-t64.
2. 3. Locate the limit switch assembly as shown, being sure to carefully center it over the stop in, drill and tap 5/16-18 x l/2" deep into two places. Install limit switch assembly. Note: For proper operation of the limit switch assembly, the electrical stop should be engaged .4" before the mechanical stop is struck. This allows for coasting of the table when the feed is on the high speed setting. Trim table stops to adjust, if required. CAUTION: Do not allow the stop piecesto strike the body of the limit switch assembly. The limit switch cable should be held off the ways using the cable clamp enclosed. Drill and tap a B-32 hole into the table to securethe cable clamp.

4.

CROSS TRAVELPOWERFEED :
l. 2. 3. Removehandwheeldial and woodruff key from cross feed leadscrew. Savekev and handwheel. Rework dial to drawing A-466. Drill and ream leadscrewfor shaft extension. Hole must be concentric to leadscrew o.d. to
within.00l T.I.R. POWER UNIT INSTALLATION: l. Slip bearing race on leadscrew against thrust collar. 2. Slide the adaptor and power feed unit against the bearing bracket. Spot the two 9/32 holes (below the center line into the bearing bracket). 3. Remove feed unit and bearing bracket. Tap U4 - 20 thread through two places. 4. Return bearing bracket and feed unit to the mill and fasten using the two U4 - 20 x l-l/2 socket head screws. (The screws may have to be shortened to clear the mounting boss for the bearing bracket.) BEVEL GEAR INSTALTATION: l. Ineert shaft extension, then drill through leadscrew with l/8 diameter drill. Pueh in l/B x 5/B roll pin - file ends smooth. 2. See attached sheet. Note feed type number for correct instructions. Add AJ863 key.

19

KNEE POWERFEED Removedial collar dial, thurst collar and endcap. t. 2. Secureinternal thruet collar. A specialset gcrewis provided for this. It will be necessary drill to through the mill in line with the center of the thrust collar. A. Measure dimensionon your mill and mark on outeideboss. B. Drill3/B Dia. throughboss. C. Drill No. 29 (.136) through collar and approximatelyl/2" into leadecrew. Tap collar 8-32 thread. D. Install 4242 Bcrew. E. Replaceendcapand externalthruet collar. 3. Reworkdial per print 4-1658. 4. Slip bearingraceon the gearshaft againstthe collar. 5. Placefeed unit over bearing race and againstthe boss.Spot the two holesthrough the unit using a 9/32 Dia. drill. Removeunit and tap Il4-2O thread, l/2" deep. Also tap gearll4-20 thread in shaft l/2" deep. DRM UNIT INSTALTATION: Replace feed unit over the race againstthe mill and eecurewith the Il4-20 x l-UA eocketcap screws. BEVEL GEAR INSTALLATION: Note feed type number for correct instructions. Utilize the shaft extensionto aid in shimming of gear. Leavethe assemblyin placeand drill through pilot hole with No. 13 (.183)drill. Reamdrill 3/f6 Dia. Insert 3/16 x l-l/4 roll pin. DIAL AND HANDCRANKINSTALTATION: Placea few ehimson the dial hub and slip on the dial. Removeshims until dial is spaced l. about Add collar. .005" from the housing. 2. Add the spring,handcrank,washerand Tru-arc. LIMIT SWITCHINSTALLATION: Limit switch on type 90 feedonly. Referto DrawingC-f94f

20

MILL POWER FEED OPERATION GENERAL - Plug the feed into a source of 120 volt, 60 cycle, AC power having a current capacity of 5 amperes. CAUTION: All electrical apparatus should be properly grounded. The feed is provided with a 3 wire cond that includes a ground terminal. Do not cut this terminal off. On installations where the cord is wired to a junction box be sure to ground the green wire. The feed direction is controlled by the main operating handle; handle to left, feed to left; handle to right, feed to right; handle in center, feed is stopped, completely disengaged and the power is turned off. Feed rate is controlled by the black center knob. Feed rate is electronically regulated, which means that the feed will remain constant at any setting regardless of load, within the capacity of the table feed. RAPID TRAVERSE: A button is provided on the table feed which allowe the feed rate to be increased to rapid without distrubing the selected feed rate. Do not hit the electrical stop in rapid traverse. OVERLOAD PROTECTION: The circuit and motor are protected by a circuit breaker which will open when the feed is under excessive load. To reset, disengage feed, wait a few minutes, then push red button on the back side of the housing. DO NOT REPEATEDLY OVERLOAD THE FEED. If the circuit breaker opens, then the cutting load should be reduced before proceeding. LIMIT SWITCHES: The limit switch is designed as a safety stop only and is not intended to be used as an accurate stop. The stopping point will be affected by the speed of the motor at the time the limit stop is struck. When the feed has shut itself off against a stop, the feed may be reversed and it will automatically feed in the direction away from the stop without having to disengagethe unit and crank away from the electrical stop. CAUTION: Do not hit stop in rapid traversemode. Feed will coast into stop and may be damaged. CAUTION: Do not allow this feed to drive into any positive stop as damage to the feed and the milling machine may result. Always leave the stops eet to where they will at least prevent the feed from feeding against the end of the table travel. CAUTION: Every attempt has been made to seal this feed. However, excessiveamounts of coolants can work their way in and ultimately damage the feed. For long life, keep the unit as dry as possible. Wipe down at the end of each day. MOTOR BRUSHES: The motor is a commutator type with the brushes accessiblefrom the outside. The replacement brush is available from your dealer or the factory. Please provide the serial number of your feed with your onder. LUBRICATION: At assembly and every three months thereafter, greaEe the roller bearing and bevel gear with bearing grease. Every three months of operation, remove the bottom coyer and greasethe large spur gear. DO NOT OVER-GREASE THE SPUR GEAR. Damage to the motor may result. NOTE: The small hole on the back of the feed near the top is a drain hole. Do not attempt to oil machine through this hole. Damage will result. NOTE: Connect to ll0 volt, 50/60 cyele power only.

21

l. 2. 3. 4.

INSTRUCTIONSFOR INSTALLING RIGHT ANGLE ATTACHMENT Tighten the set screw located between the two holding cap screws to spread the casting for ease of assembly. Secure the attachment arbor on the spindle by means of the draw bar provided, but do not lock it too tight. Once the taper is properly seateda snug fit will suffice. Loosen the center set screw. Securethe attachment in position by tightening the cap screws. CAUTION: If the set screw is not releasedprior to securing the cap screws,the attachment will be twisted and severelydamaged. ATIGNING THE ATTACHMENT AND OUTBOARD SUPPORT Insert the drive arbor in the attachrnent spindle, and re-position the outboard support until the pilot of the arbor tits the bearing properly. Place an indicator in the maehine table with its pointer againstthe side of the arbor. Feed the table in and out, and re-position the turret of the machine until the arbor is at a true 90 Deg. angleto the in/out table movement.

l. 2. 3.

PARTS ORDERS and better service will result when ordering repair parts if you will adhere to the following Quicker instructions. These sevenrequirements are essential: Give complete serialnumber of machine. l. 2. Give part name and number. State quantity wanted. 3. 4. Specify how and where to ship - Do not say "Ship the quickest way". Be definate and state agency desired, that is - air mail, parcel post (special delivery), parcel post (regular), express, motor freight, rail freight, etc. 5. List each specific individual piece or assembly that is required in the order. If only certain parts of a unit are required, never use the wond "complete", it dways raisesa question as to how much of a unit to supply. Parts must be ordered through Powermatic Burke Dealers. 6. 7. Give your Complete Address,zip code and telephone number.

TROUBLESHOOTING
CHATTER
A . I n c o r r e c t S p e e do r F e e d B. Lack sf Rigidity in Set Up C o n s u l t m i l l i n g f e e d a n d s p e e dt a b l e s f o r c o r r e c t s e t t i n g R e d u c e t o o l a n d / o r q u i l l o v e r h a n g s ,a d d a d d i t i o n a l c h a m p i n g and/or back-up work piece. Reduce fued rate and depth of cut L o c k i n h o l d e r o r c h a n g et o p r o p e r h o l d e r Tighten draw bar or check for damagedthreads on draw bar or i n h o l d e r . C h e c k h o l d e r a n d s p i n d l et a p e r f o r f l a w s o r d i r t . R e p l a c e if reou ired L o c k a l l m o t i o n s n o t u s e d : q u i l l , t a b l e , s a d d l e ,o r k n e e Adiust all gibs Lock overarm to column and head to overarm

C. Tool Loose in Holder D. Draw Bar Loose

E. Unused Motions Not Locked F. LooseGibs G. Loose Overarmor Head

2.

R E SPINDLE UNNOUT XCEEDSTD.


A . S p i n d l e B e a r i n g sL o o s e B. Bad or Incorrect Bearings A d j u s t p r e l o a d p e r m a i n t e n a n c em a n u a l R e p l a c eb e a r i n g s

22

(cont'd. TROUBLESHOOTING )
3.
S P I N D L ER U N S H O T A. Excessive reload P Reducepreload to the setting indicated in the maintenance manual C h e c k f o r o v e r fi l l i n g w i t h g r e a s e r f o r n o l u b r i c a t i o n o R e p l a c eb e a r i n g

B. Incorrect Lubrication C. Bad Bearing 4. END PLAY IN SPINDLE No Preload

Adjust preload to the setting indicated in the maintenance manual T i g h t e n f r o n t c a p w i t h a s p a n n e rw r e n c h . l t s h o u l d l o c k u p o n t h e b e a r i n g s ,n o t a g a i n s tt h e f a c e o f t h e q u i l l

B. Front Cao Loose

END PLAY IN OUILL.ADJUSTMENT' A. Worn Nut or Screw (Fine Feed) B . W o r n G e a r s( F i n e F e e d ) C . E x c e s s a c k l a s h n G e a r s( F i n e F e e d ) B i R e o l a c en u t a n d / o r s c r e w R e p l a c eg e a r s U s i n g a 5 / 1 6 a l l e n w r e n c h l o o s t e nt h e ' s e t s c r e w i n t h e a d j u s t i n g nut at the bottom of the quill cover by holding the adjustingnut w i t h a s p a n n e rw r e n c h , A d j u s t t h e n u t u s i n g t h e s p a n n e rw r e n c h and then re-lock the set screw Adjust gearby unlocking set screw in cover and rotating eccentric b u s h i n gw h i l e h o l d i n g q u i l l h a n d w h e e l r o m r o t a t i n g f

D . B a c k l a s hB e t w e e n G e a r a n d R a c k ( R a p i d F e e dO u i l l )
o,

SLIDES LOOSE A . T a b l e G i b ( S t d . )L o o s e R e m o v e s a d d l eh a n d w h e e l ,d i a l a n d s c r e w . R e m o v e t a b l e a n d s a d d l e a s s e m b l ya n d p l a c e o n t h e f l o o r o r t a b l e . A d j u s t g i b b y b a c k o u t t h e s e t s c r e w s( 3 ) a n d t i g h t e n i n gt h e c a p s c r e w s( 4 ) . R e i n s t a l lt a b l e s a d d l ea n d h a n d w h e e l a s s e m b l v A d j u s t g i b b y b a c k i n g o f f t h e s e t s c r e w s( 3 ) a n d t i g h t e n i n g d o w n t h e c a p s c r e w s( 4 ) . U n l o c k t h e j a m n u t s o n t h e ( 7 ) q i b a d j u s t i n gs e t s c r e w so n t h e left sideof the knee.Starting with the top and bottom set screw adiust in until it binds up the kneeand then back off until the k n e e m o v e s f r e e l y . L o c k t h e i a m n u t . F i n i s h a d j u s t i n gt h e b a l a n c e o f t h e s c r e w si n t h e s a m e f a s h i o n . o n e a t a t i m e Remove left end handcrank and dial loosten set screw in threaded collar. Adjust collar to minimize end play and lost motion in dial Remove handwheel and dial unlock set screw in threaded collar Adjust collar'td minimizeend play and lost motion in dial. Adjust split saddle nut by tightening the cap screw in the column side of the nut Remove outside collar and dial. Unlock set screw in threaded collar and adjust collar to minimize end play and lost motion in dial. lf Lost motion is still excessive crewand nut worn and s may need to be replaced

B . S a d d l eG i b ( S t d . ) L o o s e

C. Knee Gib (Std.) Loose

7.

E N D P L A Y I N M O T I O NS C R E W S
A. End Play in Table Screws

B . E n d P l a y i n S a d d l eS c r e w

C. End Playin KneeAdjustmenl

8.

HEADNOTSOUARE O TABLE T
A. Head not Square Left to Right C l a m p a n i n d i c a t o r i n t h e s p i n d l e s o .t h a t i t c a n b e u s e d t o t r a m the table zurface. Maximum error allowed is .001/foot. Loosten t h e t h r e a d o f t h e f o u r h e a d c o v e r i n g s c r e w s .B a c k o f f o n t h e f o u r t h b o l t b u t k e e p i t s n u g . R e a l l i g nh e a d a n d r e l o c k t h e f o u r m o u n t i n g screws Unclamp compound overarm by loosening the two cap screw on each side of the trunnion only enough to allow motion with a 3/8 allen wrench. Rotate the head and check by traming with an indicator mounted on the spindle. Maximum error allowed .001/foot

B. Head not Square Front to Back (On M a c h i n e sE q u i p e d w i t h C o m p o u n d Overarms)

23

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