Manual No. M-508Litho in U.S.A.
Part No. M -0009500-0508June, 2010
Information in this manual is subject to change without notice.
This manual covers installation, operation, maintenance, and parts list for
Bridgeport Series I milling machines with serial numbers ending with the let
ter "M". The machine serial number is located on the front of the knee. If the
machine serial number does not end with the letter "M", refer to the latest
version of manual M -0009500-0450.
In no event will Hardinge Inc. be responsible for indirect or consequential
damage resulting from the use or application of the information in this man
ual.
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Reproduction of this manual, in whole or in part, without written permis
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sion of Hardinge Inc. is prohibited.
ORDERING REPLACEMENT PARTS
Please provide the following information when ordering replacement parts:
1. The complete machine serial number. The machine serial number is located on the front of the
knee.
2. List the following:
A) Manual Number (M-508).
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.
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.
4. Keep all parts of your body away from moving parts (belts, cutters, gears, etc.)
5. Use proper point of operation safeguarding.
These and other safety precautions are discussed in the American National Standard Institute
standard entitled safety requirements for the construction, care, and use of drilling, milling, and
boring machines (ANSI B11-8-1983).
This publication is available from:
American National Standards Institute
25 West 43rd Street, 4th floor
New York, NY 10036
Safeguarding for protection at the point of operation can only be designed and constructed when
the parameters of the particular operation have been determined. As a result, ANSI B11.8-1983,
Section 5.1, states that “it shall be the responsibility of the employer to provide, and ensure use of, a
guard, guarding device, awareness barrier, awareness device, or shield…”
To assist machine users in designing point of operation safeguarding for their specific machine
applications, the Occupational Safety And Health Administration has published a booklet entitled
Concepts and Techniques of Machine Safeguarding (OSHA Publication No. 3067).
This publication is available from:
The Publication Office – OSHA
U.S. Department of Labor
200 Constitution Avenue, NW
Washington, D.C. 20210
The general purpose point of operation shield provided with this machine and shown in certain
illustrations throughout this manual may not be appropriate and cannot be utilized for all possible
applications of the machine. Use additional or alternate safeguarding where this shield is not
appropriate or cannot be utilized. Note that for purposes of display, the shield has been removed in
certain other illustrations in this manual.
M-508i
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.
In situations where inattention could cause either personal injury or damage to the equipment, a
warning notice is used.
- NOTE -
Notes merely call attention to information that is especially significant in under
standing and operating the equipment.
This document is intended for the use of those who install, operate and maintain the milling
machine. Although reasonable care has been exercised in the preparation of this manual to make it
complete and accurate, this manual does not purport to cover all conceivable problems or
applications pertaining to this machine.
-
iiM-508
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.
DO NOT OPERATE EQUIPMENT unless proper maintenance has been regularly performed
and the equipment is known to be in good working order.
DO NOT ALLOW the operation or repair of equipment by untrained personnel.
WARNING or INSTRUCTION TAGS are mounted on the equipment for your safety and infor
mation. Do not remove them.
DO NOT OPERATE EQUIPMENT if any unusual or excessive heat, noise, smoke, or vibra
tion occurs. Report any excessive or unusual vibration, sounds, smoke, or heat as well as any
damaged parts.
WEAR SAFETY GLASSES with side shields and SAFETY SHOES with steel toes and oil-re
sistant soles at all times. When necessary, wear respirator, helmet, and ear muffs or plugs.
DO NOT OPERATE ANY MACHINE while wearing rings, watches, jewelry, loose clothing,
neckties, or long hair not contained by a net or shop cap.
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-
-
-
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DO NOT WEAR GLOVES while operating equipment. Gloves are easily caught in moving
parts.
REMOVE ANY LOOSE PARTS OR TOOLS left on machine or in the work area before operating the machine. Always check the machine and work area for loose tools and parts, especially after work has been completed by maintenance personnel.
REMOVE CHUCK WRENCHES before starting the machine.
NEVER OPERATE A MACHINE after taking strong medication, using non-prescription drugs
or consuming alcoholic beverages.
SAFEGUARD THE CUTTING ZONE (“point of operation”). Use standard, general purpose
safeguards when possible. Use special safeguards when required.
PROTECT YOUR HANDS. Stop the spindle completely before changing tools.
PROTECT YOUR HANDS. Stop the spindle completely before loading or unloading a
workpiece.
DO NOT REMOVE CHIPS with hands. Use a hook or similar device and make certain that all
machine movements have ceased.
DO NOT ADJUST tooling, workpieces or coolant hoses while the machine is running.
PROTECT YOUR HANDS. Stop the spindle completely before taking measurements.
PROTECT YOUR HANDS. Stop the spindle completely before opening safeguards or covers.
NEVER REACH around a safeguard.
M-508iii
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.
KEEP WORK AREA WELL LIGHTED. ask for additional light if needed.
DON’T SLIP. Keep your work area clean and dry. Remove chips, oil and obstacles.
NEVER LEAN ON your machine. Stand away when the machine is running.
MAKE CERTAIN that you are clear of any “pinch points” created by moving slides before
starting the machine.
PREVENT OBJECTS from flying loose. Securely clamp and locate workpiece. Use stop
blocks where necessary. Keep clamps clear of cutter path.
PREVENT CUTTER BREAKAGE. Use correct table feed and spindle speed for the job. Re
duce feed and speed if you notice unusual noise or vibration.
PREVENT CUTTER BREAKAGE. Rotate spindle in clockwise direction for right-hand tools,
counterclockwise for left-hand tools. Use the correct tool for the job.
PREVENT WORKPIECE and cutter damage. Never start the machine when the cutter is in
contact with the workpiece.
DO NOT USE worn or defective tools. Use the proper size and type of tool for the task at
hand.
KEEP ROTATING CRANKS AND HANDWHEELS well lubricated and maintained. Do not re-
move safety springs.
CERTAIN MATERIALS, such as magnesium, are highly flammable in dust and chip form. See
your supervisor before working with these materials.
PREVENT FIRE. Keep flammable liquids and materials away from work area and hot chips.
PREVENT MACHINE from moving unexpectedly. Disengage power feed when not being used
(manual machines only).
PREVENT MACHINE from moving unexpectedly. Always start machine in manual mode.
UNLESS OTHERWISE NOTED, all operating and maintenance procedures are to be per
formed by one person. To avoid injury to yourself and others, be sure that all personnel are
clear of the machine when opening or closing the coolant guard door and any access covers.
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ivM-508
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.
This booklet provides basic information for the installation and use of the general purpose
safeguard. It also contains the names of several manufacturers of other types of point of operation
safeguarding for vertical milling machines.
Remember, point of operation safeguarding is your responsibility as the employer/user. You are in
the best position to evaluate your safeguarding needs and ensure that the proper safeguards are
installed and used.
- CAUTION -
A safety shield is supplied for protection from chips and coolant with every
machine.
The chip and coolant shields have been designed and are custom manufac
turedwiththehighestclearimpactmaterialcommerciallyavailable:
polycarbonate (G.E. Lexan). It has an impact strength 5 to 10 times greater
than acrylic (plexiglass) or butyrate (UVEX) materials, thereby offering the
greatest protection for our customers.
Some of the new “easy to dispose of” coolants and/or cutting oils contain
chemicalsharmfultopolycarbonate.Thesechemicalsare:
Mono-ethanolamine, Di-ethanolamine, Tri-ethanolamine and the combination
thereof. These chemicals may significantly reduce the impact strength of the
shield within days, and could destroy the entire shield in weeks.
Use of use of coolants and/or cutting oils containing these chemicals will
void the warranty on your safety shield, and could cause injury to your workers.
- WARNING -
This safeguard DOES NOT take the place of any other safety practice or
safety equipment.
YOU MUST ALWAYS wear safety glasses and safety shoes.
YOU MUST ALWAYS stop the spindle of the machine completely before
changing or adjusting the workpiece, fixture, or tool.
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YOU MUST NEVER wear gloves, long sleeves, long hair, rings, watches,
neckties, jewelry or other loose items.
M-508v
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 assembles shown in Figures I.I and I.II, like all safeguards, will be suitable
for some operations, but not for others. Carefully analyze the operation to be performed before
deciding whether this safeguard is suitable. Adjust the safeguard to suit your special requirements. If
you find that it is not suitable for a particular application, you should use an alternate form of
protection.
Installation for Machines with R-8 Spindle Taper
There are two tapped holes in the nose cap of the spindle to be used for mounting the guard (the
two untapped holes serve to remove the nose cap with a spanner wrench).
1. Place the mounting ring (Item 11) underneath the top of the guard (Item 7).
2. Place two socket head cap screws (Item 12) through the holes in the ring, and hand-start them
into the threaded holes in the nose cap until hand tight.
3. Align guard to be square with table of machine (unless angular mounting is desired).
4. Tighten screws with a hex Allen wrench.
7
6
9
2
11
12
10
1
Figure I.I - Spindle Guard Assembly
(R8 Spindle)
3,4,5
8
TP5262A
viM-508
Installation for Machines with Erickson #30 Quick Change Spindles
1. Remove the spindle locknut. This is done by removing the long button head black finish screw,
which is normally left of the cadmium-finished button head screw on the locknut of the spindle.
This will allow you to unscrew the locknut by turning it counter-clockwise.
2. Place the nose cap mounting ring “O” up against the quill nose cap and install the four button
head cap screws “M”.
- NOTE -
The counterbored side of the nose cap mounting ring fits against the nose cap.
Observe the orientation of the mounting holes in the spindle and the mounting ring
to orient the quill guard as desired.
3. Place the mounting ring (Item 11) on the top of the guard (Item 7).
4. Place the locking ring (Item 12) underneath the top of the guard (Item 7).
5. Secure the two rings together with four #8-32 x 5/8 button head cap screws.
6. Lower the quill.
7. Position the guard under the spindle.
8. Use four #8-32 x 1/2 button head cap screws to secure the guard to the spindle.
9. Reinstall the quick change locknut. Refer to assembly instructions.
7
3,4,5
8
6
9
2
13
11
TP5263A
14
12
10
1
Figure I.II - Spindle Guard Assembly
M-508vii
Guard Assembly Component Lists
BP 11060813 – R-8 SHIELD ASSEMBLY
Refer to Figure I.I.
ItemPart NumberDescriptionQty
1BP 11191203Shield Assembly, Rear1
2BP 11010060Screw, Hand 8-32 x .5004
30300312Screw, BHC 10-32 x .7504
4BP 11010065Washer, Plastic #10-328
5BP 11010055Nut, Stop, #10-32 (Elastic)4
6BP 11060824Shield, Right Side1
7BP 11060817Shield Assembly, Top1
8BP 11010063Screw, Drive, "Type U" #12 x .6252
9BP 11060820Shield Assembly, Front1
10BP 11060822Shield, Left Side1
11BP 11191201Ring, Guard Mounting1
120100610Screw, SHC 1/4-20 x 5/82
BP 11060814 – QUICK CHANGE SHIELD ASSEMBLY
Refer to Figure I.II.
ItemPart NumberDescriptionQty
1BP 11191203Shield Assembly, Rear1
2BP 11010060Screw, Hand 8-32 x .5004
30300312Screw, BHC 10-32 x .7504
4BP 11010065Washer, Plastic #10-328
5BP 11010055Nut, Stop, #10-32 (Elastic)4
6BP 11060824Shield, Right Side1
7BP 11060816Shield Assembly, Top1
8BP 11010063Screw, Drive, "Type U" #12 x .6252
9BP 11060820Shield Assembly, Front1
10BP 11060822Shield, Left Side1
11BP 12190330Ring, Guard Mounting1
12BP 12190331Ring, Guard Locking1
130300208Screw, BHC #8-32 x 1/24
140300210Screw, BHC #8-32 x 5/84
viiiM-508
- NOTES -
M-508ix
- NOTES -
xM-508
Table of Contents
CHAPTER 1 - INSTALLATION
Uncrating ....................................1-1
Shortages ....................................1-1
Cleaning ....................................1-1
Positioning the Head Upright ...........................1-2
Lifting the Machine................................1-4
Foundation ...................................1-5
Placing on a Solid Foundation .........................1-5
Leveling Bolts and Pads ..........................1-5
General Speed Recommendations .......................5-5
Table of Cutting Speeds and Feeds ......................5-5
M-508xiii
- NOTES -
xivM-508
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. In
case of shortages, report them immediately to the representative from whom the machine was
purchased, indicating the parts not received which have been checked on the packing list.
CLEANING
Thoroughly clean protective coating from the machine with a suitable cleaning solution.
- WARNING -
DO NOT use gasoline or any other flammable cleaning agent to clean machine.
- NOTE -
Do not move the table, saddle, knee,
or any moveable part until all ways
have been well cleaned and lubricated.
1. After initial cleaning, move table, saddle and
knee in one direction by hand to limit stop.
2. Clean and lubricate the exposed ways.
3. Move each unit to the opposite limit stop, and
clean and lubricate the exposed ways.
4. Move each unit to the opposite stop once more
and similarly clean and lubricate the exposed
ways.
5. Loosen bolts to unlock the ram, and move it
forward and backward to the full length in order
to clean and lubricate.
TP5277
Figure 1.1 - Milling Machine
Left Side View
M-5081-1
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. Using a (1-inch) wrench, remove the retaining
lead screw nut and install the hand cranks properly.
Loosen four head mounting bolts “C”, Figure 1.3, and pull stop pin “A”, Figure 1.2, out to detent
and rotate head attachment using the swivel bolt “B”, Figure 1.3, in either direction until it has been
moved within approximately 20% of vertical. It is recommended supporting the head by hand to
relieve the weight on the swivel bolt, as a safety precaution, push the stop pin back in. Continue to
raise the head attachment to vertical position. Align the indicator on the head attachment with the
ZERO line on the ram adapter scale. Tighten all nuts first to 25 lb-ft torque in a diagonal sequence,
then to 50 ft/lbs.
- NOTE -
Care should be taken to avoid excessive pressure since this will cause distortion in
the quill.
1. Lower knee approximately 6” (150mm).
2. Withdraw the safety pin on the left-hand side of ram adapter.
3. Loosen the four unit head mounting bolts.
4. Support unit head manually and use a spanner on swivel bolt to wind into upright position.
5.
Press the safety pin back into the ram adapter after passing the 25° mark.
6. Tighten bolts first to 25 lb-ft torque in a diagonal sequence as noted in Figure 1.4, then to 50
lb-ft. Overtightening could cause bind in the quill movement.
B
A
C
Aligning
Faces
Swiveling Head
To Swivel the Head More Than 25°, the
Safety Pin “A” Must be Pulled Outwards
Figure 1.2 - Positioning Head
TP5278A
Figure 1.3 - Positioning Head
Left View
1-2M-508
Table
TP5278B
Front View
4
1
Figure 1.4 - Tightening Sequence
2
3
TP5280
M-5081-3
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
1-4M-508
FOUNDATION
PLACING ON A SOLID FOUNDATION
- NOTE -
It is recommended that the machine be secured to the floor to prevent movement
or tipping due to off-center loading. It is the customers responsibility to supply all
necessary hardware if the machine is to be secured to the floor.
When setting machine on a concrete foundation, it is advisable to use grout (thin
mortar) to take care of any unevenness in the concrete as well as to provide a
solid foundation at all points.
Leveling Bolts and Pads
The machine is supplied with leveling bolts and pads. Thread the bolts through the tapped holes in
the base and position on the machine on the pads. Refer to Figure 1.6. Level the machine as outlined
on the next page.
Machine Hold-Down Bolts
When setting machine on a floor than has any surface irregularities, shims should be used to
correct this condition to the greatest extent possible.
If securing machine to floor with hold-down bolts, make certain that all four corners are making
contact with the floor after machine is leveled. If above condition is not met, it is possible to twist the
column and put a bind into ways.
The machine should be placed on a solid level floor with shims or anti-vibration pads as shown in
Figure 1.7 to insure machine base is positioned evenly.
Leveling
Bolt
Hold-Down
Bolt
Leveling
Pad
Figure 1.6 - Leveling Bolts and Pads
M-5081-5
TP8006
Figure 1.7 - Hold-Down Bolts
Shims
TP5281
LEVELING THE MACHINE
Set machine by leveling the work table lengthwise and crosswise with a precision instrument as
shown in Figure 1.8.
Level
Level
Figure 1.8 - Leveling the Machine
TP5282
1-6M-508
MACHINE POWER SUPPLY
- WARNING -
Machine must be connected 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. Connect machine wiring to power supply making sure connection is in compliance with safety
regulations.
3. Check for correct spindle rotation. In the HIGH SPEED range, the spindle should rotate
clockwise when viewed from the top of the machine.
- NOTE -
Drum switch and Hi-Neutral-Lo lever must be in Hi range when checking spindle
rotation.
M-5081-7
LUBRICATION
1
3
4
Lubrication
Instruction Plate
2
Recommended Lubrication
Few Drops Twice Daily
Figure 1.9 - Lubrication Requirements
IndicatorLubrication AreaType of Lubrication
1Way Surfaces and Lead ScrewsSunoco Waylube #1180 or equivalent
2Milling Heads (Spindle Bearings)
3MotorNone required. Motor greased for life of bearings
4
Not ShownPower FeedOil to sight level with Mobilube No. 46 S.A.E. 140
Not ShownShaping AttachmentMobil 600W Oil or equivalent
S.A.E. 10 or 10W Light Oil
(None on grease-packed heads)
Lubricate with grease every six months as described on
lubrication plate
TP5283
1-8M-508
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. Loosen four locknuts but
leave drag on same for fine adjustment. To square head to table in the longitudinal axis, mount
indicator as shown in Figure 1.10. For general milling use, graduations provided on the head are
close enough.
Tighten the four head locknuts in a diagonal order as previously described on page 1-2. Tighten
the three ram locking bolts to 50 lb-ft.
- CAUTION -
Do not operate the machine until properly lubricated.
Adjustable
Worm Shaft
3 Ram
Locking Bolts
Zero
Head Alignment Y-Axis
Zero
Figure 1.10 - Head Alignment for Y and X Axis
Vertical Adjustable
Worm Shaft
Ram
Ram Adapter
Aligning
Faces
Zero
Head Alignment X-Axis
Locknuts
Zero
TP5284
M-5081-9
- NOTES -
1-10M-508
CHAPTER 2 - OPERATION
HEAD CONTROLS
R
Q
A
B
C
D
E
G
F
P
O
N
M
L
H
I
J
K
TP5285
Figure 2.1 - Head Controls Parts Assembly
M-5082-1
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