JET 690178, 691171, 690408, 690141, 690068 User Manual

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Operating Instructions and Parts Manual

Variable Speed Turret Mill

Model JTM-4VS

Shown with option al acce ss ori es X-Ax is Ta ble Power fe ed and D RO

JET

Warranty and Service

JET® warrants ever y pro duct it sells against m anufactu rers ’ defect s. If one of our to ols need s ser vice o r repa ir, 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. JET woodworking machinery is designed to be used with Wood. Use of these machin es in the processi ng of m etal, plastics, or other m aterials o utside recomm ended gu idelines m ay voi d the warra nty. The exceptions are acrylics and other natural items that are made specifically for wood turning.

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 initial p u rchase when calli ng. If a prod uct r equ ires further inspection, the Technical Service representati ve 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 Informat io n

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

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.

Section Page

Warranty and Servic e ...................................................................................................................................... 2

Warnings ...................................................................................................................... .................................. 4

Introduction ..................................................................................................................................................... 6

Specifications .................................................................................................................................................. 6

Unpacking ....................................................................................................................................................... 7

Contents of the Shipping Container.............................................................................................................. 7

Set-up and Installation .................................................................................................................................... 8

Preparing the Milling Machine for Service .................................................................................................... 8 

JTM-4VS Dimensions ..................................................................................................................................... 9

JTM-4VS Overview and Terminology ............................................................................................................ 10

Electri c al Connec tions ................................................................................................................................... 11

General Electr ic al Cautions .................................................................................................................... 11

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

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

Operating Instruct io n s ................................................................................................................................... 11

Operating Controls .................................................................................................................................... 11

Motor Switch ............................................................................................................................................. 11

Variable Speed Control .............................................................................................................................. 12

Spindle Br a ke ............................................................................................................................................ 13

High-Neutral-Low Shift Lever ..................................................................................................................... 13 

Quill Power Feed Lever ............................................................................................................................. 13

Feed Rate Lever ........................................................................................................................................ 13 

Feed Trip Cam Lever ................................................................................................................................. 14

Feed Directi on Contr ol ............................................................................................................................... 14

Coarse Feed Handle.................................................................................................................................. 14

Quill Lock Lever ......................................................................................................................................... 14

Micrometer Adjusting Nut........................................................................................................................... 14

Fine Feed Handwheel................................................................................................................................ 14

Depth Scale and Stop ................................................................................................................................ 15

Power Feed Operation ............................................................................................................................... 15

Draw Bar Operati on - Changi ng Tooling..................................................................................................... 16

Clamping Work Piece to the Table ............................................................................................................. 16

Adjustments .................................................................................................................................................. 16

Mill Head – Left/Right Adjustment .............................................................................................................. 16

Mill Head – Fore/Aft Adj ustm ent................................................................................................................. 17

Positioning the Ram .................................................................................................................................. 18

Positioning the Ram Fore and Aft ........................................................................................................... 18

Positioning the Ram on its Turret............................................................................................................ 18

Gib Adjustment .......................................................................................................................................... 18

Adjustment of Knee Gib ......................................................................................................................... 18

Adjustment of Saddle Gib ....................................................................................................................... 18

Adjustment of Table Gib ......................................................................................................................... 18

Power Feed Trip Lev er Mechanism............................................................................................................ 19 

Table Lead Scr ew Backlash Adjustment .................................................................................................... 19

Cross Feed Backl ash Adjustment ........................................................................................................... 19

Longitudinal B ac klash Adjustment .......................................................................................................... 19 

Maintenance ................................................................................................................................................. 21

Lubrication................................................................................................................................................. 21

Periodic Maintenance Requirements ...................................................................................................... 21

Replacement of Drive Motor ...................................................................................................................... 22

Replacement of Vari - S peed B elt ................................................................................................................ 23 

Replacement of Br ak e S hoes, S pri ngs and/or Tim ing Belt.......................................................................... 23

Replacement of Q uill Feed Clock Spring .................................................................................................... 24

Replacement Parts........................................................................................................................................ 24

Head Assembly ......................................................................................................................................... 25

Parts List for Head Assembly ..................................................................................................................... 26

Spindle Assembly ...................................................................................................................................... 29

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Base Assembly .......................................................................................................................................... 33

Parts List for Base Assembly ..................................................................................................................... 34

Lead Screw Assembly ............................................................................................................................... 36

One-Shot Lubric ation System .................................................................................................................... 37

Electri c al Connec tions – Single Phase only................................................................................................ 38

Electri c al Connec tions – 3 Phase only ....................................................................................................... 39

Warnings

1. Read and understand the ent ire owner’s manual before att empting assembly or operation.

2. Read and understand t he warnings posted on t he machine and in this manual. Failur e to comply with all of these warnings may c ause serious i njury.

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

4. This turret mill is designed and intended for use by properl y trained and experienced per sonnel only. If you are not familiar with the proper and safe operation of a turret mill, do not use until proper training and knowledge have been obtained.

5. Do not use thi s turret mi ll for other than its int ended use. If used for other purpo ses, JET, disclaims any real or implied warranty and holds itself harmless fr om any injury that m ay resul t from that use.

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6. Always wear approv ed safety glasses/f ace shields while using t his turret mill. ( Everyday eyeglasses only have impact resistant lenses; they are not safety glasses.)

7. Bef or e operat ing t his turret mil l, remov e ti e, rings, watc hes and ot her j ewel ry, and rol l sleev es up past t he elbows. Remov e all loose clothing and confine long hair. Non-slip footwear or anti-skid floor strips are recommended. Do not wear gl ov es.

8. Wear ear protector s (plugs or muffs) during extended peri ods of operation.

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

• Lead from lead based paint.

• Crystalli ne sil ic a from bricks, cement and other masonry pr oduc ts.

• Arsenic and chromium from chemically treated lumber .

Your risk of exposure vari es, depending on how of t en you do this type of work. To r educe your ex posure to these chemic als, work i n a well -venti l ated area and work wit h approv ed saf ety equipment, such as f ace or dust masks that are specif ically designed to filter out mic r oscopic particles.

10. Do not oper ate this machine while tir ed or under the influence of drugs, alcohol or any medication.

11. Mak e c ertain the switch is in the OFF positi on before connecting the m achi ne to t he power supply.

12. Mak e c ertain the machine is properl y grounded.

13. Mak e all machine adjustments or maintenance with the machine unplugged f r om the power source.

14. Remov e adjusting keys and wrenches. For m a habit of checki ng to see that keys and adjusting wrenches are removed from the machine before turning it on.

15. Keep safety guards in place at all times when the machine is in use. If remov ed for maintenance purposes, use extreme caution and replace the guards immedi ately.

16. Some cool ants used for machini ng contai n chemicals that may be hazardous to your health if not used properly. Read and under stand all information on the coolant container and protect your self accordingly.

17. Check damaged parts. Before further use of the mac hine, a guard or other part that is damaged should be carefully c hecked to determine that it will operate properly and perform it s intended f unction. Check for alignment of m oving part s, bindi ng of m oving part s, breakage of parts, m ount ing and any other c ondit i ons that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced.

18. Pr ov ide for adequate space surroundi ng work ar ea and non-glare, ov er head lighting.

19. Keep the floor around the machi ne cl ean and free of scrap material, oil and grease.

20. Keep v isitors a safe distance from the work area. Keep children away.

21. Give your work undivided attention. Looking around, carrying on a conversation and “horse-play” are careless acts that can r esul t in serious injury.

22. Maint ain a balanced stanc e at all times so that you do not fall or lean against the c utters or other moving parts. Do not overr eac h or use excessive force to perform any machine oper ation.

23. Use the right tool at the correct speed and feed rat e. Do not forc e a tool or attachment to do a job for which it was not designed. T he ri ght tool will do the job better and mor e safely.

24. Use recom mended accessories; improper accessories may be hazar dous.

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

26. Turn off the machine and disconnect from power before cleaning. Use a brush or compressed air to remove chips or debris — do not use your hands.

27. Do not stand on the machine. Serious injur y c oul d oc c ur if the mac hine tips over.

28. Never leav e the machine running unattended. Turn the power off and do not l eav e the machine until it comes to a complete stop.

29. Remove loose items and unnecessary work pieces from the area befor e start ing the machine.

Familiariz e you rself with the following safety noti ces used in this manual:

This means that if pr ecautions are not hee ded, it m ay result in mi nor injur y and/or possible

machine damage.

This means that if precautions are not heeded, it may result i n serious or even fatal injury.

Introduction

This manual is provided by JET, c overing the safe operat ion and maintenance pr ocedures for a JET Model JTM-4VS Turr et Milling M achi ne. This m anual contai ns inst ructi ons on instal lati on, safety pr ecautions, gener al operating proc edures, mai ntenance instructi ons and parts breakdo wn. This m achine has been de signed and constructed to pr ovide years of troubl e free operati on if used in accor dance wit h instructi ons set fort h in this manual. If there are any questions or comments, please contact either your local suppli er or J ET. JE T c an also be reached at our web site: www.jet tools.com.

Specifications

Model Number ..................................................................... JTM- 4VS -1 ............................................. JTM-4VS-3

Stock Number ............................................................................ 690180 .................................................. 690182

Spindle Taper .................................................................................. R-8 ......................................................... R - 8

Diameter of Quill (in.) .................................................................... 3.375 ...................................................... 3.375

Number of Spindl e Speeds........................................................ Variable .................................................. Var iable

Range of Spindle Speeds (RPM ) ............................................60 to 4200 ............................................... 60 to 4200

Downfeeds per Revolution of Spindle (in.) ............. 0.0015, 0.003, 0.006 ............................... 0.0015, 0.003, 0.006

Spindle Travel (in.) ............................................................................... 5 ............................................................. 5

Head Movement – Left and Right ( deg.) ............................................. 90 ........................................................... 90

Head Movement – Fore and Aft ( deg.)................................................ 45 ........................................................... 45

Maximum Distance Spindle to Table (in.)...................................... 17-1/2 ..................................................... 17-1/2

Maximum Distance Spindle to Column (in.) ........................................ 19 ........................................................... 19

Minimum Distance Spindle to Column (in.) ..................................... 4-1/2 ....................................................... 4-1/2

Collet Capacity (in.) .................................................................. 1/8 – 7/8 ..................................................1/8 – 7/8

Table Size (in.) ..............................................................................9 x 49 ...................................................... 9 x 49

Longitudinal Table Travel, maximum (in. ) ........................................... 34 ........................................................... 34

Table Cross Travel, maximum (in.) ..................................................... 12 ........................................................... 1 2

Number of T-Slots ................................................................................ 3 ............................................................. 3

T-Slot Size (WxD)( in .) ............................................................... 5/8 x 3/4 .................................................. 5/8 x 3/4

T-Slot Centers (in.) ......................................................................... 2-1/2 ....................................................... 2- 1/2

Table Load, maximum (l bs.) ............................................................. 660 ........................................................ 660

Knee Travel, m aximum (in.) ......................................................... 1 4-1/2 ..................................................... 14-1/2

Ram Travel, maximum (in.) .......................................................... 13 -3/8 ..................................................... 13- 3/8

Overall Dimensions (in.) .............................................. 66W x 63D x 85H .................................... 66W x 63D x 85H

Motor ................................................. TEFC 2HP, 1PH, 115/230V, 60Hz .......... TEFC 3 HP, 3PH, 230/460V, 60Hz

(prewired 230V) (prewired 230V)

Net Weight, approx. (lbs.) .............................................................. 2,420 ...................................................... 2,420

The abov e specifi cations were current at the t ime this manual was publ ished, but because of our policy of continuous im provement, JET reserv es the right to change specifi cations at any time and wit hout prior notice, without inc ur ri ng obligations.

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 Turret 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 instruct ions.

Contents of the Shipping Container

Note: Some parts may be pre- ins talled on the mill.

1 Turret Mill ( not shown) 1 Flat Way Cover 1 Pleated Way Cover 1 Draw Bar

3 Table Adjustment Handles 1 Tool Box, containing:

1 Hex Key Set (1.5-10mm) * 1 17/19mm Box Wrench * 1 Cross Point Screw Driv er #2 * 1 Flat Blade Scr ew Driver #2 * 1 Plastic Oil Bottle * 1 Elevating Cr ank Handle 1 Handwheel 1 Coarse Feed Handle 1 Can White Touch Up Paint 1 Eye Bolt 1 Operator’s Manual ( not shown) 1 Warranty Car d (not shown)

* parts with an asteris k are also inc luded in the tool box service k it, p/n JTM4VS-TB.

Figure 1

Read and understand the entire contents of this manual before attempting set-up or

operation ! Failure to comp ly may cause serious injury.

If your mill is supplied with an optional Table Powerfeed and/or DRO, be sure to consult the separate instruction materials that accompany them.

Set-up and Installation

and-aft leveling. Be certain you get it level in BOTH directions.

Preparing the Milling Machine for Service

1. Remove any crating which m ay be covering the machine on the pallet .

2. Remove accessory items from the pallet or machine tabl e. Compare t hese items wit h the list on the previous page.

3. Check the ti ghtness of the lif ting ring on the r am to be certain it i s tight.

4. Check the tightness of the lock handles on the ram (see Figure 23) to be certain the ram is locked tight.

5. Rem ove the nuts and/or bolts, which secure the machine to the pallet.

6. Center an overhead crane or other suitable overhead lifting device and sling arrangement over the lifting ring.

Note: This machine weighs over 2400 pounds! Be certain the lifting arrangement is new or in excellent condition and has a safety factor that will account for age, difficulties in lifting, etc. When lifting using the ring, the machine will tip forward. If y ou wish, y ou c an mi nimize this tipping by rigging a support sling over the front of the machine. B e careful when doing t his, to prevent the sling f rom damaging any com ponents on the front of the machi ne. Be sure to steady the mill t o prevent it from spinning.

7. Lift the machine off the pallet no higher than necessary to cl ear the hold- down hardware, then pull the pall et out of the way. Do NOT get hand s or feet underneath the machine when rem oving the pallet!

8. Put the machine base over the hold-down system where the mac hine will be spotted. Anchor bolts of suffici ent size and length must be fast ened to the floor ac cording to the footprint of the mill. See diagram on page 10.

Note: The accompanying diagrams show you the maximum dimensions of the machines with the table, ram, etc., fully extended in all possible directions. W hen spotting t he machine be cert ain to leave room not only for the machine itself, but also for operator clearance and clearance for workers servic ing the machine, and any unusual sizes of workpieces that might extend off the machine’s tabl e.

9. W hen the machine i s over its anchor s, lev el the machine using shim s under the corners needi ng them. The machinist’s level used for leveling should be placed on the table. The table is the referenc e surface for both side-to-side and fore-

Mill must be supported equally under all f our corners. Failure to comply may cause the column to twist and put a bind in the table ways.

10. When the machine is level, secure the base to

the anchor system.

IMPORTANT: Before attempting to raise the mill head, refer to Mill Head – Left/Right Adjustment in the Adjustments section for procedures to safely raise and set up the mill head.

11. Loosen the four hex head nuts (see A, Figure 22)

about 1/4 turn each (counterclockwise), just enough to allow rot ation of the head.

12. While assisting the worm mechanism by putti ng

upward pressure on the m otor by hand, use the wrench supplied with the machine to turn the worm nut and raise the head to upri ght position.

13. Tighten the headbolts slightl y — not torqued —

just snug.

14. Using mineral spirits or other cleaning solvent,

clean all of the rust proofing from where it may have been appli ed. Thi s is import ant; movi ng the table or any other components bef ore removing the rust proofi ng will onl y put rust proofi ng where you don’t want it.

Some of the following steps may have already been performed on t he mac hine. If so, ign ore the instructions related to those particular steps. Otherwise, perform them in the order listed, referring to Figure 11 for any clarification.

15. Install the table traverse and cross-feed cranks

on their respective shafts using the nuts on the shafts to secure the c r ank s.

16. Rem ove any rust proofing from t he drawbar and

its washer, and put the drawbar with washer installed into the spindle c enter through the top of the machine.

17. Slide the fine feed handwheel over the

handwheel hub and push it back until its rollpin engages the hole in the hub and the wheel is flush with the hub surf ac e.

18. Put t he coarse f eed handl e on the feed shaft and

tap it li ghtl y until it s roll pi n engages a hole i n t he hub and it is flush against t he hub surface.

19. Unwrap and c lean the knee crank and install it on

it s shaf t .

20. I nstall the rubber way cov ers at front and behind

the table.

JTM-4VS Dimensions

Figure 2: Installation Diagram

JTM-4VS Overview and Terminology

Figure 3: Overview

Electrical Connections

Operating Instructions

All electrical connections must

be made by a qualified electrician! Failure to comply may cause seriou s injury!

General Electrical Cautions

This machi ne must be grounded i n accordance with the National Electrical Code and local codes and ordinances. Thi s work should be done by a qual ifi ed electrici an. The machine must be gr ounded to protect the user from elect ri c al shock.

Wire Sizes

For circuit s 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 prevent motor ov erheating and burnout, the use of wir e 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

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

The JTM-4VS has been pre-wired for 230 volt operation. To c hange from 230V to the other voltage offered, r emove the junction box cov er on the motor and change the wires accordi ng to t he diagram found on the inside of the cover.

Before connecting to the power source, make sure that the switch is i n the off posi tion.

The mill must be properly grounded.

230/460 Volt Lines 120 Volt Lines

AWG Number

Figure 4

Operating Controls

The lubricati on system is a manuall y operated, oneshot system requiring operator intervention. The operator must lower the one-shot lever to lubricate the machine ways and ball screws. The one-shot lubricati on system reserv oir i s loc ated on t he left side of the machine.

The positi on of the milli ng machine mill head can be set up to accommodate the work piece being machined. T he mill head can be set up for angl es to the left or ri ght and for for e and aft angl es. The mill head can also be rot ated on its turret. The r am can be moved back and forth to reach work piece locations at the fore and aft extremes of worktable travel. Refer to the Adjustments section.

Motor Switch

The Motor Switch is on the upper left-hand si de of the mill head (Fi gure 5). The switch has three po sitions: FWD (forward), STO P, and RE V (reverse).

Setting the switch to FWD will provide clockwise spindle rotation. Use FWD for normal, right-hand tooling.

FWD (clockwise) operation occurs only when the gearbox is in the low speed position. When the gearbox is in high-speed position, the motor switch must be in t he REV position t o provide ri ght-hand or clockwise rotation. Refer to Figure 6 for a chart of required switch positions.

The motor switc h controls a three-pha se motor. The motor can be switched f rom FW D to REV and back with the motor running, and will reverse direction when the switch setting is changed. At higher speeds, this may put strain on the timing belt but there will be no damage to the motor or gear mechanism.

Check for proper spi ndle rotation in the high-speed range. The spindle should rotate clockwise when viewed from the top of the machine. If the spindle rotates counter-clockwise, disconnect from power and switch two of the three power l eads.

Lubrication

Do not operate the mill before lubricating the machine fully. Failure to comply may cause damage to the machine.

Refer to the Maintenance/Lubrication section and make sure the machi ne has been fully lubricated before operating.

Figure 5

Figure 6

Variable Speed Control

Change speed only while the spindle is turning.

The vari-speed handwheel (A, Figure 7) is used to control the spindle speed. The speeds for high and low speed ranges are displayed on t he panel on the front of the mill head ( B, Figure 7).

All speed changes m ust be made while the motor is running. Attempting speed changes without the motor running can result in damage to the drive mechanism.

Figure 7

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