JET 690082, 691187, 691191, 690157, 690161 User Manual

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Operating Instructions and Parts Manual

Step Pulley Turret Mill

Model JTM-1, JTM-2

Model JTM-1 shown

JET

1.0 Warranty and Service

JET® warrant s ever y pro duct i t sell s against m anuf actu rers’ defec ts. If one of ou r tools needs ser vice or rep air, please contact Technical Service by calling 1-800-274-6846, 8AM to 5PM CST, Monday through Friday.

Warranty Period The general warranty lasts for the time period specified in the literature included with your product or on the official JET branded website.

• JET products carry a limited warranty which varies in duration based upon the product. (See chart below)

• Accessories carry a limited warranty of one year from the date of receipt.

• Consumable items are defined as expendable parts or accessories expected to become inoperable within a

reasonable amount of use and are covered by a 90 day limited warranty against manufacturer’s defects.

Who is Covered

This warranty covers only the initial purchaser of the product from the date of delivery.

What is Co vered

This warranty covers any defects in workmanship or materials subject to the limitations stated below. This warranty does not cover failures due directly or indirectly to misuse, abuse, negligence or accidents, normal wear-and-tear, improper repair, alterations or lack of maintenance.

Warranty Limitations

Woodworking products with a Five Year Warranty that are used for commercial or industrial purposes default to a Two Year Warranty. Please contact Technical Service at 1-800-274-6846 for further clarification.

How to Get Technical Support Please contact Technical Service by calling 1-800-274-6846. Please note that you will be asked to provide proof of initia l p u rch a s e whe n calling. If a product requires further inspection, the Technical Service representative will

explain and assist with any additional action needed. JET has Authorized Service Centers located throughout the United States. For the name of an Authorized Service Center in your area call 1-800-274-6846 or use the Service Center Locator on the JET website.

More Informa tion

JET is constantly adding new products. For complete, up-to-date product information, check with your local distributor or visit the JET website.

How State Law Appli es

This warranty gives you specific legal rights, subject to applicable state law.

Limitations on This Warranty

JET LIMITS ALL IMPLIED WARRANTIES TO THE PERIOD OF THE LIMITED WARRANTY FOR EACH PRODUCT. EXCEPT AS STATED HEREIN, ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXCLUDED. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

JET SHALL IN NO EVENT BE LIABLE FOR DEATH, INJURIES TO PERSONS OR PROPERTY, OR FOR INCIDENTAL, CONTINGENT, SPECIAL, OR CONSEQUENTIAL DAMAGES ARISING FROM THE USE OF OUR PRODUCTS. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.

JET sells through distributors only. The specifications listed in JET printed materials and on official JET website are given as general information and are not binding. JET reserves the right to effect at any time, without prior notice, those alterations to parts, fittings, and accessory equipment which they may deem necessary for any reason whatsoever. JET

Product Listing with Warranty Period

90 Days – Parts; Consumable items; Light-Duty Air Tools 1 Year – Motors; Machine Accessories; Heavy-Duty Air Tools; Pro-Duty Air Tools 2 Year – Metalworking Machinery; Electric Hoists, Electric Hoist Accessories 5 Year – Woodworking Machinery Limited Lifetime – JET Parallel clamps; VOLT Series Electric Hoists; Manual Hoists; Manual Hoist Accessories; Shop Tools; Warehouse & Dock products; Hand Tools

NOTE: JET is a division of JPW Industries, Inc. References in this document to JET also apply to JPW Industries, Inc., or any of its successors in interest to the JET brand.

branded products are not sold in Canada by JPW Industries, Inc.

2.0 Table of contents

Section Page

1.0 Warranty and Service ..................................................................................................................................... 2

2.0 Table of contents ............................................................................................................................................ 3

3.0 Safety warnings .............................................................................................................................................. 4

4.0 About this manual .......................................................................................................................................... 5

5.0 JTM-1, JTM-2 installation layout .................................................................................................................... 6

6.0 Specifications ................................................................................................................................................. 7

7.0 JTM-1/JTM-2 Features and Terminology ....................................................................................................... 8

8.0 Setup and Assembly ...................................................................................................................................... 9

8.1 Unpacking .................................................................................................................................................. 9

8.2 Contents of shipping container ................................................................................................................... 9

8.3 Site preparation ........................................................................................................................................ 10

8.4 Lifting the mill ........................................................................................................................................... 10

8.5 Completing assembly ............................................................................................................................... 10

8.6 Lubrication ................................................................................................................................................ 11

9.0 Electrical connections .................................................................................................................................. 11

9.1 Wire Sizes ................................................................................................................................................ 11

10.0 Controls ...................................................................................................................................................... 11

11.0 Operations .................................................................................................................................................. 13

11.1 Operating precautions ............................................................................................................................ 13

11.2 Clamping workpiece to table .................................................................................................................. 13

11.3 Changing speed range ........................................................................................................................... 13

11.4 Setting up for fine hand feed .................................................................................................................. 13

11.5 Setting up for automatic feed ................................................................................................................. 14

11.6 Power feed operation ............................................................................................................................. 14

11.7 Draw bar operation; changing tooling ..................................................................................................... 15

12.0 Adjustments ............................................................................................................................................... 15

12.1 Head movement: left and right ............................................................................................................... 15

12.2 Head movement: Fore and aft ................................................................................................................ 16

12.3 Positioning ram ....................................................................................................................................... 16

12.4 Feed trip adjustment ............................................................................................................................... 16

12.5 Gib adjustment ....................................................................................................................................... 17

12.6 Table lead screw backlash adjustment .................................................................................................. 17

13.0 Maintenance ............................................................................................................................................... 19

13.1 Lubrication .............................................................................................................................................. 19

13.2 Periodic Maintenance Activities .............................................................................................................. 19

14.0 Belt position – speed ranges ...................................................................................................................... 20

15.0 Replacement Parts ..................................................................................................................................... 20

15.1.1 Upper Head Assembly – Exploded View ............................................................................................. 21

15.1.2 Upper Head Assembly – Parts List ..................................................................................................... 22

15.2.1 Head Assembly – Exploded View ....................................................................................................... 24

15.2.2 Head Assembly – Parts List ................................................................................................................ 25

15.3.1 Base Assembly – Exploded View ........................................................................................................ 28

15.3.2 Base Assembly – Parts List ................................................................................................................. 29

15.4.1 Table Leadscrew Assembly – Exploded View ..................................................................................... 31

15.4.2 Table Leadscrew Assembly – Parts List ............................................................................................. 31

15.5.1 One-Shot Lubrication System – Exploded View .................................................................................. 32

15.5.2 One-Shot Lubrication System – Parts List .......................................................................................... 32

16.0 Electrical Connections ................................................................................................................................ 33

3.0 Safety warnings

1. Read and understand the entire owner's manual before attempting assembly or operation.

2. Read and understand the warnings posted on the machine and in this manual. Failure to comply with all of these warnings may cause serious injury.

3. Replace the warning labels if they become obscured or removed.

4. This turret mill is designed and intended for use by properly trained and experienced perso nnel on ly. If you are no t fam iliar w ith the proper and safe operation of a turret mill, do not use until proper training and knowledge have been obtained.

5. Do not use this turret mill for other than its intended use. If used for other purposes, JET, disclaims any real or implied warranty and hold s itself harmles s from a ny injury t hat may result from that use.

6. Always wear approved safety glasses/face shields while using this mill. Everyday eyeglasses only have impact resistant lenses; they are not safety glasses.

7. Before operating this machine, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothi ng a nd confine long hair.

8. Non-slip safety footwear and anti-skid floor strips are recommended. Do not wear gloves.

9. Never place hands near or around a revo lving tool or part.

10. Wear ear protectors (plugs or muffs) during extended periods of operation.

11. Some dust created by power sanding, sawing, grinding, drilling and other construction activities contain chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

• Lead from lead based paint.

•

Crystalline silica from bricks, cement and other masonry products.

•

Arsenic and chromium from chemically treated lumber.

Your risk of exposure varies, depending on how often you do this type of work. To reduce your exposure to these chemicals, work in a well-ventilated area and work with approved safety equipment, such as face or dust masks

that are specifically designed to filter out microscopic particles.

12. Do not operate this machine while tired or under the influence of drugs, alcohol or any medication.

13. Make certain the switch is in the OFF po sition before connecting the machine to the power supply.

14. Make certain the machine is properly grounded.

15. Make all machine adjustments or maintenance with the machine unplugged from the power source.

16. Workpiece must be attached or clamped to the table. Never hold a workpiece with your hand.

17. Use correct spindle speed and table feed for the particular job.

18. Do not start machine with cutter in contact with workpiece.

19. Disengage power feed when not in use.

20. Remove adjusting keys and wrenches. Form a habit of checking to see that keys and adjusting wrenches are removed from the machine before turning it on.

21. Keep safety guards in place at all times when the machine is in use. If removed for maintenance purposes, use extreme caution and replace the guards immediately after completion of maintenance.

22. Check damaged parts. Before further use of the machine, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced.

23. Provide for adequate space surrounding work area and non-glare, overhead lighting.

24. Keep the floor around the machine clean and free of scrap material, oil and grease.

25. Keep visitors a safe distance from the work area. Keep children away.

26. Make your workshop child proof w ith padlocks, master switches or by removing starter keys.

27. Give your work undivided attention. Looking around, carrying on a conversation and “horseplay” are careless acts that can result in serious injury.

28. Maintain a balanced stance at all times so that you do not fall into the cutter or other moving parts. Do not overreach or use excessive force to perform any machine operation.

29. Use the right tool at the correct speed and feed rate. Rotate spindle clockwise for righthand tools, counterclockwise for left-hand tools. Do not force a tool or attachment to do a job for which it was not designed. The right tool will do the job bette r and more safely.

30. Use recommended accessories; improper accessories may be hazardous.

31. Frequently clean this machine. Maintain tools with care. Keep cutters sharp and clean for the best and safest performance. Follow instructions for lubricating and changing accessories.

32. Turn off the machine before cleaning. Use a brush or compressed air to remove chips or debris — do not use your hands.

Familiarize yourself with the following safety notices used in this manual:

33. Do not stand on the machine. Serious injury could occur if the machine tips over.

34. Never leave the machine running unattended. Turn the power off and do not leave the machine until it comes to a complete stop.

35. Remove loose items and unnecessary work pieces from the area before starting the machine.

36. Don’t use in dangerous environment. Don’t use this machine in damp or wet locations, or expose it to rain. Keep work area well lighted.

37. Some coolants used for machining contain chemicals that may be hazardous to your health if not used properly. Read and understand all user information listed on the coolant container and protect yourself accordingly.

This means that if precautions are not heeded, it may result in minor injury and/or

possible machine damage.

This means that if precautions are not heeded, it may result in serious injury or

possibly even death.

4.0 About this manual

This manual is provided by JET covering the safe operation and maintenance procedures for a JET Model JTM-1 and JTM-2 Turret Mill. This manual contains instructions on installation, safety precautions, general operating procedures, maintenance instructions and parts breakdown. Your machine has been designed and constructed to provide years of trouble-free operation if used in accordance with the instructions as set forth in this document.

If there are questions or comments, please contact your local supplier or JET. JET can also be reached at our web site: www.jettools.com.

Retain this manual for future reference. If the machine transfers ownership, the manual should accompany it.

Read and understand the entire contents of this manual before attem pting assembly

or operation! Failure to comply may cause serious injury!

5.0 JTM-1, JTM-2 installation layout

Figure 1

6.0 Specifications

Mode l Number .......................................................................................... JTM-1............................................ JTM -2

Stock Number ......................................................................................... 690082........................................... 690089

Motor an d Electricals:

Motor type ............................................................................................ induction....... T EFC induction, capacito r start

Horsepowe r ......................................................................................... 2 (1.5kW)....................................... 2 (1.5k W)

Phase ............................................................................................................... 3............................................. single

Voltage ............................................................................................... 230V only.............. 115/230V (prewired 230V)

Cycle ..........................................................................................................60Hz.............................................. 60Hz

Listed FLA (full load amps) ....................................................................... 6.5/5.6..............................................28/14

Start Capacitor................................................................................................. --........................... 500MFD 125VAC

Power Transfer ............................................................................................. belt................................................. belt

Motor Speed .............................................................................. 3450/1720 RPM...................................... 1720 RPM

Sound Emission (tested at 3 ft. from machine):

Without loa d.......................................................................................... 75 dB............................................. 75 dB

With load ......................................................................................... 80-85 dB........................................ 80-85 dB

Head and Spindle:

Spind le Taper ............................................................................................... R-8................................................. R-8

Spindle bearings ...................................................................................... clas s 7........................................... class 7

Quill Diameter ............................................................................................ 3-3/8 ”............................................. 3-3/ 8”

Number of Spindle Speeds.............................................................................. 16.................................................... 8

Range of Spindle Speeds:

Low (RPM) ............................................ 80,135 ,2 10 ,32 5 ,660 ,1 11 0 ,17 50 ,2 720 .............................. 8 0,13 5 ,21 0 ,325

High (RPM) ................................ 160, 270, 420, 650, 1320, 2220, 3500, 5440....................... 660,1110,1750,2720

Downfeed Distance per Revolution of Spindle ................... 0.0015”, 0.003”, 0.006”................... 0.0015”, 0.003”, 0.006”

Spindle Travel .................................................................................................5”................................................... 5”

Head Movement ...........................................................90° L and R, 45° F and B................ 90° L and R, 45° F and B

Maximum Distance Spindle to Table ......................................................... 17-1/2”........................................... 17-1 /2”

Maximum Distance Spindle to Column ........................................................... 19”................................................. 19”

Minimum Distance Spindle to Column ........................................................ 4-1/2”............................................. 4 -1/2”

Collet Capacity ................................................................................... 1/8” – 7/8”.......................................1/8” – 7/8”

Ram Travel .............................................................................................. 13-3/8”........................................... 13-3 /8”

Ram Rotation ...................................................................................90° L and R.................................... 90° L and R

Table:

Table Size ................................................................................................ 9”x42”............................................ 9 ”x42”

Longitudinal Table Travel ......................................................................... 23-7/8”........................................... 23-7/8”

Table Cross T ra vel .................................................................................. 12-1/2”.................. ......................... 1 2-1 /2”

T-Slots, Number ............................................................................................... 3.................................................... 3

T-Slots, Size ................................................................................................. 5/8”................................................ 5/8”

T-Slots, Spacing ........................................................................................ 2-1/2 ”............................................. 2-1/ 2”

Maximum Table Load ............................................................................... 550 lb............................................. 550 lb

Knee Travel ............................................................................................. 14-1/2”........................................... 1 4-1/2 ”

Dimensions:

Overall Dimensions, assembled ........................................... 57”W x 64”D x 82”H........................ 57”W x 64”D x 82”H

Shipping Dimensions ........................................................... 67”W x 56”D x 66”H........................ 67”W x 56”D x 66”H

Weights:

Net Weight (a p prox .) ............................................................................... 2056 lb........................................... 2056 lb

Shipping Weight (appro x) ........................................................................ 2200 lb........................................... 2200 lb

The specifications in this manual were current at time of publication, but because of our policy of continuous improvement, JET, reserves the right to change specifications at any time and without prior notice, without incurring obligations.

7.0 JTM-1/JTM-2 Features and Terminology

1. Motor

2. Lifting ring

3. Ram

4. Ram locking handle (x2)

5. Turret scale

6. Ram movement lever

7. Column

Figure 2: Features and Terminology (JTM-1 shown)

8. Table long i tudi nal cr ank hand le (x2)

9. Power connection box

10. Base

11. Filter screen (x2) (for use with optional flood coolant systems)

12. Elevating leadscrew

13. Crossfeed handle

14. Knee crank handle

15. Pleated way cover

16. Table l o c king hand le ( x 2 )

17. Flat way cover

18. Spindle

19. Head Assembly (see section 10.0 for explanation of controls)

20. Motor junction box

21. Knee

22. Holes for mounting bolts (x4)

23. Knee locking handle (x2)

24. Saddle locking handle

25. One-shot lube system

26. Lubrication chart

8.0 Setup and Assembly

8.1 Unpacking

Open shipping container and check for shipping damage. Report any damage immediately to your distributor and shipping agent. Do not discard any shipping material until the T urret Mill is assembled and running properly.

Compare the contents of your container with the following parts list to make sure all parts are intact. Missing parts, if any, should be reported to your distributor. Read the instruction manual thoroughly for assembly, maintenance and safety instructions.

8.2 Contents of shipping container

Note: Some par ts may be pre-installed on the mill.

1 Turret Mill (not shown) 1 Flat Way Cover 1 Pleated Way Cover 1 Draw Bar 3 Table Adjustment Handles 2 Belt Guards 1 Tool Box, containing (Figure 3):

1 Hex Key Set (1.5-10mm) * 1 17/19mm Box Wrench * 1 Cross Point Screw Driver #2 * 1 Flat Blade Screw Driver #2 * 1 Plastic Oil Bottle * 1 Elevating Crank Handle 1 Handwheel 1 Coarse Feed Handle 1 Can White Touch Up Paint 1 Hoisting Ring 1 Operator’s Manual (not shown) 1 Warranty Card (not shown)

* parts with an asterisk are also included in the tool box service kit, p/n JTM4VS-TB.

Figure 3: shipping contents

NOTE: If your mill is supplied with an optional Table Powerf eed and/or Digital Readout, be sure to consult the separate instruction materials that accompany them.

8.3 Site preparation

The mill must be placed o n an even surface and bolted to the floor. Anchor bolts of sufficient size and length must be f astened to the f loor according to the mill’s footprint. See the site installation diagram in Figure 1.

8.4 Lifting the mill

Finish removing the sides of the crate. Leave mill bolted to pallet until ready to move to its final location.

The preferred method for lifting mill is with a hook through the hoisting ring screwed into t he tapped hole atop the ram. Steady mill to prevent it from spinning.

An alternative method for lifting mill is with a sling. Follow diagram in Figure 1 for proper position of sling under ram. Note position of ram and that table has been moved against column. Tighten ram locking bolts (A, Figure 4) before lifting.

cause the column to twist and put a bind in the ways.

8.5 Completing assembly

Before attempting to raise mill

head, familiarize yourself with instructions in section 12.1, for procedures to sa fely raise a nd set up the mill head.

1. Loosen four hexagonal nuts (see A, F igure 9) about 1/4 turn each counterclockwise, just enough to allow rotation of head.

2. Apply upward pressure on motor by hand to relieve pressure on worm mechanism, and use supplied wrench to turn worm nut and raise head to upright position.

3. Slightly tighten nuts (A , Figure 9); not torq ued, just snug. Before operating mill, follow

procedures in section 12.1 to verify angle settings and properly tighten the four nuts.

4. Use mineral spirits, kero sene or other cleaning solve nt , to rem o ve all rust- p r oo fing from wher e it may have been applied. This is important; moving the table or any other components before removing rust proofing will only put rust proofing where you don’t want it. (Do not use gasoline, paint thinner, or lacquer thinner; these will damage painted surfaces. )

Figure 4: sling location

Carefully lift mill and move to a position over the anchor bolts. Lower mill over anchor bolts and check for leve l, with a machi nist’s level plac ed on the table. Mill must be level back to fro nt and side to side. Shim if necessary, but remember that mill must be supported equally at all four corners. Check for level before tightening anchor bolt nuts, and check again after tightening them.

It is advisable when plac ing the mill on a concrete floor to use grout (thin mortar) to correct any unevenness in the concrete and provide a solid foundation at all points.

Mill must be supported equally

under all four corners. Failure to comply may

5. Lubricate exposed ways (see sect. 13.0), then move each unit (table and ram) to the opposite limit stop, and clean and lubricate the newly exposed ways. Loosen bolts to unlock ram and move it forward and backward to the full length in order to clean and lubricate.

6. Cover all machined surfaces with a film of light machine tool oil to inhibit rust.

Some of the following steps may have already been performed on the machi ne. If so, ig nore the instructions related to those particular steps. Otherwise, perform them in the order listed. Refer to Figures 2 and 5 to help locate items.

7. Install the table traverse and cross-feed handles on their respective shafts. Tighten each handle using a wrench on the flats.

8. Remove any rust proofing from drawbar. Install drawbar with its washer into spindle center through top of head assembly. When installing tool into spindle, lock spindle and tighten drawbar using provided wrench.

9. Slide the fine feed handwheel over the hub and push it back until its roll pin engages hole in hub, and handwheel is flush with hub surface.

10. Place coarse feed handle on feed shaft, alig ning rol l pin w ith a hole . Tap hand le lig htl y until it is flush against hub surface.

11. Unwrap and clean elevating (knee) crank and insta l l it o n its shaft .

12. Install rubber way covers at front and behind table.

13. Install belt guards.

8.6 Lubrication

Do not operate this milling

machine before fully lubricating it. Failure to comply may damage machine.

prevent motor overheating and burnout, the use of wire sizes for branch circuits or electrical extension cords according to the following table is recommended:

Conductor Length

0 – 50 Ft. No. 14 No. 14 50 – 100 Ft. No. 14 No. 12 Over 100 Ft. No. 12 No. 8

230/460 Volt Lines 120 Volt Lines

AWG Number

Table 1

Familiarize yourself with all lubricating points in section 13.0, and fully lubricate this machine before operating it.

9.0 Electrical connections

All electrical connections must be made by a qualified electrician in compliance with all relevant codes. This machine must be properly gro unded. Failure to comply may result in serious injury.

Confirm that power at the site matches power requirements of the mill before connecting to power source.

The JTM-1 turret mill is rated at 2HP, 3PH, 230V only.

The JTM-2 turret mill is rated at 2HP, 1PH, 115/230V and comes from the factory prewired at 230V.

To convert from 230V to 115V operation (JTM-2 only):

1. Open junction box on motor and change the

wires according to diagram found on inside of cover.

10.0 Controls

Refer to Figure 5:

2. Open Fwd/Rev switch box and change

connections according to diagram.

Similar diagrams are found in section 16.0 of thi s manual. Note: If discrepancies arise, diagrams on machine take precedence.

It is recommended that the JTM-1 be connected to a dedicated 10 amp circuit with a circuit breaker or time-delay fuse. Connect the JTM-2, using 230 volt power, to a dedicated 40 amp circuit with circuit breaker or time-delay fuse, and the JTM-2 with 115 volt power, to a dedicated 30 amp circuit with circuit breaker or time-delay fuse. Local codes take precedence over recommendations.

9.1 Wire Sizes

For circuits which are far away from the electrical service box, the wire size must be increased in order to deliver ample voltage to the motor. To minimize power losses and to

Figure 5: controls

A. Motor Lock (Belt Tension) Levers (A, Figure

5) – Slide levers to loosen motor mounting; shift motor to release tension on belts and reposition belts for different speed range.

Disconnect mill from

power source before changing belt position. Reinstall belt guards before operating mill.

B. Speed Range Selector (B) – Mill is in high

speed range when selector is in front position (facing operator). Push selector to the side to shift into low speed range. Rotate spindle to assist engagement, by either turning spindle nose by hand or turni ng drawbar knob with a wrench, provided drawbar is pulled up tightly.

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