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 optional accessories X-Axis Table Powerfeed and DRO

JET
427 New Sanford Road	Part No. M-690182
LaVergne, Tennessee 37086	Part No. M-690182
Ph.: 800-274-6848	Revision H3 01/2015
www.jettools.com	Copyright © 2015 JET

Warranty and Service

JET® warrants every product it sells against manufacturers’ defects. If one of our tools needs service or repair, 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 Covered

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 machines in the processing of metal, plastics, or other materials outside recommended guidelines may void the warranty. 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 purchase when 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 Information

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 Applies

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® 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.

Table of Contents
Section	Page
Warranty and Service......................................................................................................................................	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
Electrical Connections...................................................................................................................................	11
General Electrical Cautions ....................................................................................................................	11
Wire Sizes..............................................................................................................................................	11
Lubrication.................................................................................................................................................	11
Operating Instructions ...................................................................................................................................	11
Operating Controls ....................................................................................................................................	11
Motor Switch .............................................................................................................................................	11
Variable Speed Control..............................................................................................................................	12
Spindle Brake............................................................................................................................................	13
High-Neutral-Low Shift Lever.....................................................................................................................	13
Quill Power Feed Lever .............................................................................................................................	13
Feed Rate Lever........................................................................................................................................	13
Feed Trip Cam Lever.................................................................................................................................	14
Feed Direction Control...............................................................................................................................	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 Operation - Changing Tooling.....................................................................................................	16
Clamping Work Piece to the Table.............................................................................................................	16
Adjustments..................................................................................................................................................	16
Mill Head – Left/Right Adjustment ..............................................................................................................	16
Mill Head – Fore/Aft Adjustment.................................................................................................................	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 Lever Mechanism............................................................................................................	19
Table Lead Screw Backlash Adjustment ....................................................................................................	19
Cross Feed Backlash Adjustment...........................................................................................................	19
Longitudinal Backlash Adjustment ..........................................................................................................	19
Maintenance .................................................................................................................................................	21
Lubrication.................................................................................................................................................	21
Periodic Maintenance Requirements ......................................................................................................	21
Replacement of Drive Motor ......................................................................................................................	22
Replacement of Vari-Speed Belt................................................................................................................	23
Replacement of Brake Shoes, Springs and/or Timing Belt..........................................................................	23
Replacement of Quill Feed Clock Spring....................................................................................................	24
Replacement Parts........................................................................................................................................	24
Head Assembly .........................................................................................................................................	25
Parts List for Head Assembly.....................................................................................................................	26
Spindle Assembly......................................................................................................................................	29

Base Assembly..........................................................................................................................................	33
Parts List for Base Assembly .....................................................................................................................	34
Lead Screw Assembly ...............................................................................................................................	36
One-Shot Lubrication System ....................................................................................................................	37
Electrical Connections – Single Phase only................................................................................................	38
Electrical Connections – 3 Phase only .......................................................................................................	39

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 personnel 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 this turret mill for other than its intended use. If used for other purposes, JET, disclaims any real or implied warranty and holds itself harmless from any injury that may result from that use.

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

7.Before operating this turret mill, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair. Non-slip footwear or anti-skid floor strips are recommended. Do not wear gloves.

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

9.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.

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

11.Make certain the switch is in the OFF position before connecting the machine to the power supply.

12.Make certain the machine is properly grounded.

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

14.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.

15.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.

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

17.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.

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

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

20.Keep visitors 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 result in serious injury.

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

23.Use the right tool at the correct speed and feed rate. Do not force a tool or attachment to do a job for which it was not designed. The right tool will do the job better and more safely.

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

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 injury could occur if the machine tips over.

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

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

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

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 or even fatal injury.

Introduction

This manual is provided by JET, covering the safe operation and maintenance procedures for a JET Model JTM-4VS Turret Milling Machine. This manual contains instructions on installation, safety precautions, general operating procedures, maintenance instructions and parts breakdown. This machine has been designed and constructed to provide years of trouble free operation if used in accordance with instructions set forth in this manual. If there are any questions or comments, please contact either your local supplier or JET. JET can also be reached at our web site: www.jettools.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 Spindle Speeds........................................................		Variable ..................................................	Variable
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 ...........................................................	12
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 (lbs.) .............................................................		660 ........................................................	660
Knee Travel, maximum (in.) .........................................................		14-1/2 .....................................................	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 above specifications were current at the time this manual was published, 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.

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 instructions.

Contents of the Shipping Container

Note: Some parts 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

1Tool Box, containing:

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	Eye Bolt
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 1

Read and understand the entire contents of this manual before attempting set-up or operation! Failure to comply 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

Preparing the Milling Machine for Service

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

2.Remove accessory items from the pallet or machine table. Compare these items with the list on the previous page.

3.Check the tightness of the lifting ring on the ram to be certain it is tight.

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

5.Remove 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 you wish, you can minimize this tipping by rigging a support sling over the front of the machine. Be careful when doing this, to prevent the sling from damaging any components on the front of the machine. Be sure to steady the mill to prevent it from spinning.

7.Lift the machine off the pallet no higher than necessary to clear the hold-down hardware, then pull the pallet out of the way. Do NOT get hands or feet underneath the machine when removing the pallet!

8.Put the machine base over the hold-down system where the machine will be spotted. Anchor bolts of sufficient size and length must be fastened to the floor according 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. When spotting the machine be certain to leave room not only for the machine itself, but also for operator clearance and clearance for workers servicing the machine, and any unusual sizes of workpieces that might extend off the machine’s table.

9.When the machine is over its anchors, level the machine using shims under the corners needing them. The machinist’s level used for leveling should be placed on the table. The table is the reference surface for both side-to-side and fore-

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

Mill must be supported equally under all four 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 rotation of the head.

12.While assisting the worm mechanism by putting upward pressure on the motor by hand, use the wrench supplied with the machine to turn the worm nut and raise the head to upright position.

13.Tighten the headbolts slightly — not torqued — just snug.

14.Using mineral spirits or other cleaning solvent, clean all of the rust proofing from where it may have been applied. This is important; moving the table or any other components before removing the rust proofing will only put rust proofing where you don’t want it.

Some of the following steps may have already been performed on the machine. If so, ignore 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 cranks.

16.Remove any rust proofing from the drawbar and its washer, and put the drawbar with washer installed into the spindle center 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 surface.

18.Put the coarse feed handle on the feed shaft and tap it lightly until its roll pin engages a hole in the hub and it is flush against the hub surface.

19.Unwrap and clean the knee crank and install it on its shaft.

20.Install the rubber way covers at front and behind the table.

JTM-4VS Dimensions

Figure 2: Installation Diagram

JTM-4VS Overview and Terminology

Figure 3: Overview

Electrical Connections

All electrical connections must be made by a qualified electrician! Failure to comply may cause serious injury!

General Electrical Cautions

This machine must be grounded in accordance with the National Electrical Code and local codes and ordinances. This work should be done by a qualified electrician. The machine must be grounded to protect the user from electrical shock.

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 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.

50 – 100 Ft.

Over 100 Ft.

AWG Number

230/460 Volt Lines	120 Volt Lines
No. 14	No. 14
No. 14	No. 12
No. 12	No. 8
Figure 4

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 change from 230V to the other voltage offered, remove the junction box cover on the motor and change the wires according to the diagram found on the inside of the cover.

Before connecting to the power source, make sure that the switch is in the off position.

The mill must be properly grounded.

Check for proper spindle 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 leads.

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 machine has been fully lubricated before operating.

Operating Instructions

Operating Controls

The lubrication system is a manually 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 lubrication system reservoir is located on the left side of the machine.

The position of the milling machine mill head can be set up to accommodate the work piece being machined. The mill head can be set up for angles to the left or right and for fore and aft angles. The mill head can also be rotated on its turret. The ram 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 side of the mill head (Figure 5). The switch has three positions: FWD (forward), STOP, and REV (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 the REV position to provide right-hand or clockwise rotation. Refer to Figure 6 for a chart of required switch positions.

The motor switch controls a three-phase motor. The motor can be switched from FWD 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.

Figure 5

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

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 the panel on the front of the mill head (B, Figure 7).

All speed changes must 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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