Page 1
Page 2
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the
KEmpsmiTH snncHinE
monUFRCTURERS OF PRECISIOn BUILT
K
U. S. Hoffman Machinery Co,
219 Lamson Street
Syracuse 6, New York
Attention:
Gentlemen:
In accordance with our phone conversation
of today we are enclosing our instruction and main
tenance manual that pertains to our Maximillers
- Mr. Stahl,
ewpsmit
co.
/
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m IL LI n G mflCHIHES SinCE I 8 8 8
H
miLUUflUKEE 14, UUIS., U. S. fl.
„ Mar eft's! 9, 1947
RECEIVED
MAR 2 0 1347
Mailing Dept
Tool Supervisor
.
Referring to page 29 which is the clutch
assembly, we would suggest that you make a list
the parts that you require and either call or write
us again. It appears that the part that you require
is No. 3G210D.
and will have to make it up. However, as there was
a change made at about the time your machine was
built, we are unable to determine whether you
require a 10 or 4 spline bore.
Therefore, we would suggest that you list
the parts that you require and contact us as soon as
possible
.
We do not have this part in stock
Very truly
THE KEffiPSfttLTH MACHINE COMPANY
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LHMa<Lsack, Secy. & Treas.
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Page 4
HOW TO OPERATE AND MAINTAIN
KEMPSMITH MAXIMILLERS
***************
The Kempsmith Maximi'ller is a precision tool. Ac
curacy and alignment can only be retained with
proper care. Adjustments should not be attempted
without a complete understanding of the mechanism
involved. Continued accuracy is assured, so long
as the machine is kept to the standard of its or
iginal setting, and is not subjected to unneces
sary abuse in operation.
Kempsmith Maximillers are equipped with both over
load and safety devices to meet all the require
ments of standard operation,
however, can ’
anticipate all contingencies, and The
No amount of care,
Kempsmith Machine Company welcomes any suggestion,
or constructive criticism
intended to assist the
company in improving its product.
AM communications regarding attachments, arbors
or other equipment, as well as further information
pertaining to operation or maintenance, should in
clude the serial number of the milling machine.
This number is located on the face of the column
above the spindle on the Horizontal Maximiller,
and about l
n below the upper edge of the finished
column face on all Vertical Maximillers.
HOISTING
AND
UNLOADING
All Maximillers are equipped with an eye bolt #63,
which is in place at the top of all vertical
chines.
for this eye bolt is located 2?
On Horizontal Maximillers tne tapped hole
‘ from front face
ma
of column under the overarm #42. Be sure the rope,
cable or chain used in lifting
ample capacity.
Weights of all Maximillers are in
the machine is of
dicated in the specification sheets included in the
MaximiI Ier Bulletin.
The Vertical Maximiller lifts
bolt.
back.
To.lift Horizontal Machine: Move overarm
Install eye bolt.
in balance by the eye
Move overarm as close to
eye bolt as possible and lock in place. With rags
or block of wood protecting the exposed back end
of ways, carry back end of overhanging overarm in
a sling hitched to the same crane hook which is
hooked to the eye bolt. This limits back end sag
created by the extended overarm.
Page 5
UNCRATING
After the machine is delivered to you, remove pro
tective crating and skids.
Be careful to avoid
marking or damaging the machine. If machine is dam
aged in transit, notify both the Kempsmith repre
sentative and the transportation company immediately.
SHORTAGES
CLEANING
Check shipment carefully against the itemized pack
ing list which is included in the parts box with
the machine. Report shortages immediately to the
Kempsmith representative from whom the machine was
purchased. Make a list of the parts not received.
Kempsmith Milling Machines are shipped with all fin
ished surfaces carefully protected by a slushing
compound. Remove all traces of this slushing com
pound with either gasoline or kerosene. Do NOT move
any part of the machine until all exposed surfaces
have been thoroughly cleaned and oiled.
Remove har
ness #41 from knee, and pendants #38 and #39 from
overarm
Clean back end of overarm. Then move overarm for
ward, exposing back overarm bearing.
this bearing. Move overarm back, all the way, ex
posing
#42. Clean and oil exposed end of overarm.
Clean and oil
front bearing.
Clean and oil this bearing,
and the exposed back end of overarm.
Clean and oil exposed face and vee sides of column.
Then clean and oil the table, saddle and knee with'
component screws and all exposed surfaces.
Then by
hand, move the table, saddle and knee to the ex
treme limit stops in one direction.
Clean and oil
all exposed surfaces, repeating the process after
siiding alI units to the 'other extreme Iimit stops.
m
FOUNDATION
LEVELING
Kempsmith Maximillers are extremely rigid and ac
curate. Column and base are cast integral, and
machined on the bottom, thus assuring a level in
stallation when mounted on a flat surface.
On ir
regular floor surfaces, grouting should be applied
to eliminate the unevenness, and to provide a solid
foundation for the entire base. When installing
the machine on an upper floor, it should be located
over
a
girder, near a wall, or at some other suit
able spot where building vibrations are at a minimum.
The work table of the milling machine determines
whether or not the machine is level. Center the
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Page 6
saddle on the knee, and the table to the saddle.
Use an accurate, reliable level.
both lengthwise and crosswise of the table,
Take readings
supporting the machine base at corners on taper
wedges, taper not to exceed one-half (£") inch
per foot. After the machine is level, insert ad
ditional wedges approximately twelve (12") inches
apart around its entire base. Recheck level of
machine to make sure it was not disturbed.
heavy duty lag screws or bolts to secure machine
firmly to foundation.
If grout is applied, bolts
Use
should not be drawn up until the machine is firm-
Iy set
.
ILLUSTRATIONS
LUBRICATION
SPEED AND
FEED GEARING
AM operating points, indicated by numbers,
located on illustrations at the back of this
manual, and are for purposes of instruction only.
are
Machine repair part numbers are located on the
planograph drawings following the illustrations.
For the effective and continued operation of the
milling machine, it is imperative that all oper
ating parts be completely lubricated before the
machine is started, and this precaution should
be taken throughout the life of the machine.
The speed and feed gear units of the machine oper
ate in a bath of oil.
amp I e Iubrication to both bearings and gears,
This provides constant and
I n
addition, the front spindle bearing and the machine
drive clutch are force-feed lubricated by an
"Internal Gear Type
able speed box ft
” pump, built
7 of the machine.
into the demount
LUBRICATING
FRONT END
The lubrication of the front end of all Maximillers
is accomplished through three stations located as
foilows
:
(
I ) At right front of knee is an oil well that
lubricates all bearings in front knee box
#25.
(2) A spring top oiler lubricates the rear
knee box #56. This box is mounted on the
right rear end of knee, being the power
take-off between the slip shafts #53 and
#54, and the power feed drive shaft #59
and quick traverse drive shaft #58.-
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Page 7
(3) An oil reservoir #61, mounted on back of
saddle #60 and #76 (2 reservoirs on #5
Maximillers) lubricates the elevating
screw assembly, including the thrust
bearings and bevel gears....cross feed
screw and nut
and nuts
cIutches
saddIe
....
...
. . ..
and the bearings in the saddle box #24
. ...
IongitudinaI leadscrew
driving gear bearings and
.bearing ways of the knee and
saddIe and table travels....
mounted under right hand end of saddle.
The vertical feed or elevating screw should be kept
clean, and additional oil applied occasionally,
especially when vertical
travel is being utilized.
The same applies to the face and vee's of the
column on which the knee travels.
should be filled
at
five to eight hour intervals,
AM stations
especially #61, as the upper level of this reservoir
lubricates the longitudinal table ways only as long
as the oil level in the reservoir is above these
table ways. Gears of the front knee box and the
saddle box should be greased at 3 month intervals.
Use a good grade of cup grease, sparingIy
....
just
enough to cover the teeth, as too much grease in
these units will work into the bearing oil feed tubes.
OIL GAUGE
OIL DRAIN
LUBRICANTS
RECOMMENDED
Sight oil gauge #137 on left side of column, gauge
#17 on feed gear box, and gauge #40 on the pendants,
provide an accurate check on oil level at all times.
All reservoirs are equipped with oil drains.
The
column drain (not shown or numbered), is located in
the center at back of column. The feed box, saddle
box and front knee'box are equipped with a 1/2" pipe
plug located in the bottom of each box for oil drain
age.
The following lubrjcants,
or their equivalents, are
recommended for use in all Maximillers:
COLUMN RESERVOIR....S.A.E.
90 EP Gear OiI
FEED BOX RESERVOIR..S.A.E. 160 EP Gear Oil
FRONT END RESERVO IR
...#60 & #76
S.A.E. 30 Machine Oil
#2) 3 gal.
#4
) 5s gal.
I qt.
I Pt .
ALL OILING STATIONS...S.A.E. 30 Machine Oil
A
Page 8
CLEANING
LUBRICANT
RESERVOIRS
After the new machine has been in operation for a
period of not more than thirty (30) days, the
reservoir
in the column, the feed box #14,
knee box #55, saddle box #24 and front knee box
#25 shouId be drained
fresh oils, as specified,
fill
reservoirs with kerosene,
approximately five (5) minutes
mechanism. Drain kerosene,
cleaned and refilled with
»
After draining old oil,
Operate machine
f I ush i ng entire
?
Fill reser vo i rs with
rear
fresh oil to proper level, changing it thereafter
at ninety (90) day intervals, as previously
directed.
THE NECESSITY FOR THIS CLEANING PROCESS
CANNOT BE OVEREMPHASIZED.
OVERARM
UNIVERSAL
JOINTS AND
SLIP SHAFTS
MOTOR
CAUTION
The overarm should be kept clean and oiled at all
times.
This will prevent corrosion, increase ease
of movement, and prevent marring whenever the
pen-
dants are insta lied.
The Universal Joints (under knuckle guards #49 and
#55) and the slip shafts and sleeves #53 and #54
should be cleaned and oiled daily to -assure clean,
free act ion.
The motor is equipped with Alemite fittings which
provide lubrication for that unit, and should be
renewed at minimum six (6) month intervals.
Be sure to use a good grade of acid free mineral
oil and grease for all lubrication.
This is very
important as acids left in some oils cause pitting
of the bear i ngs .
OPERATION
The operating control of all Maximillers is con
centrated at the front of the knee. All movements
normally necessary in the course of a job are made
without requiring the operator to move from his
operating position. This includes starting and
stopping of the spindle, the starting, stopping or
reversing of all feed movements, as well as lock
ing of knee,saddle and table. The operator,
therefore, has full control of the machine at all
times, and because of the fewer and simpler move
ments required, he can greatly increase his pro-
d uction
.
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Page 9
CONTROLS
Motive power is controlled by a two (2) push
button control switch #6 mounted on the right
side of the machine on the front end of the
speed box #7, but may be relocated to suit.
Lever ff\, on the right side, on top of the
speed box on #2 and #3 Maximillers, controls
spindle starting and brake. Moving lever to
right engages the clutch.
Pressure in opposite
direction operates a friction brake. Similar
control on #4 and #5 Maximillers is obtained by
two (2) levers:
Lever #101 at front of knee,
acting from left to right, as previously stated,
and lever #94, on the right hand side of machine
under the speed box. This enables the operator
to control spindle action from a position back
of the machine work table.
SPINDLE
REVERSE
UNIVERSAL
MILLING
MACHINE
The main drive clutch #||, vee belt pulley sheave,
or chain drive sprocket must run in the direction
indicated on the clutch cover #44 at all times.
Spindle direction of rotation is obtained by
changing position of lever #10 on the side of the
speed box. These positions are marked "std" and
"Rev " If the clutch teeth do not engage readily,
engage the drive clutch slightly (just enough to
shift the clutches).
The reverse clutch should
then engage eas i I y .
Operation of the Universal Maximiller is identi
cal to that of the Plain Maximiller,
It differs
only in the fact that the table may be swiveled
fifty
(50°) degrees in either direction from the
straight plaae, and is locked in place by two
sets of swivel- locks....the lower, #77, with two
(2) nuts on each side of the knee under the
saddle, and #79 locking at two (2) places at
front of the swivel block #80-
HORIZONTAL
TABLE TRAVEL
Controlled by lever #35 for feed, and lever #34
for quick traverse on plain Maximillers.
These
levers are located at front of plain saddle #62
in the saddle cover #30. On the Universal Maxi-
miller,
at side of Universal Saddle Box #73. Lifting
above travel is controlled by lever #70
front end of this handle engages the quick trav
erse only as long as handle is held in place.
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Page 10
When released, handle drops into "FEED" position
where it is held in place by a spring located at
bottom
of
saddle box. Directional travel and
neutral are obtained through lever #82 located at
center front of universal swivel block #80. Table
travels in direction in which lever #82 is thrown.
TRANSVERSE
AND VERTICAL
TRAVEL
SAFETY LOCK
Controlled by one set of levers located on the side
of the front knee box #25, at right side of knee.
The upper lever #27 operates the feed. The lower
lever #26 operates the quick traverse.
Choice of
unit to be operated is made by pulling out the knob
located close to the respective screw or pinion.
Viz:
Knob #120 close to cross feed screw #119 en
gages the clutch for transverse, or cross feed, of
the saddle on the knee. Knob #121 close to ele
vating pinion shaft #122 engages the clutch for
vertical travel of the knee on the face of the col
umn. Direction of travel is indicated under all
handles, and is constant regardless of direction of
spindle rotation, if motor is properly connected.
To prevent engaging both the feed and the quick
traverse simultaneously a Safety Lock has been pro
vided, being located on the bottom outside of the
saddle cover #30 for horizontal travel, and on the
side of the front knee box #25 for transverse and
verticaI traveI
.
FEED AND
QUICK
TRAVERSE
SAFETY
STOPS •
All feed and quick traverse actions are reversible,
each on its individual levers.
Safety Stops #36 on the horizontal travel of the
Plain Maximiller, and #81 on the horizontal travel
of the Universal Maximiller, with #118 on the
transverse, and #134 or. the vertical
travel of all
type Maximillers, afford a positive trip within
one-eighth (1/8") inch of limit of feed or quick
traverse in all directions. These stops are pinned
solidly in place. Under no circumstances should
any of these stops be removed. Neither should any
of the units be pulled beyond this point by hand,
as this will spring the timing cams and permit the
units to feed past these safety points in future
operations
.
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Page 11
SAFETY
SPRINGS
Crank Handles on all Maximillers are equipped with
Safety Springs to keep the handles disengaged when
not in actual use. Under no circumstances should
these springs be removed, as the crank handles can
then remain engaged, constituting a definite and
extreme hazard to the operator, or to any person
near the machine when quick traverse is utilized.
COOLANT
SPEED
CHANGES
FEED
CHANGES
Coolant Pump #21 is located in the right hand rear
corner of the column, directly under feed box #14.
When not required, pump may be disconnected by
raising clutch #20 up on shaft.
Machine must be
shut down to engage or disengage this clutch.
Spindle speed changes are affected by sliding gears
controlled by handles #8 on the outside of speed
box #7, located on right side of machine. Select
speed desired on the speed index plate #9. Main
drive clutch must be disengaged when shifting gears.
If teeth meet so gears wi I I not siide
clutch lightly,
shifting gear train enough to per
, engage main
mit gears to slide into position.
Feed changes are affected in the same manner as the
speed changes. Select feed desired on the feed in
dex plate #13 on feed box #14, and move feed change
hand I eg #16 to position indicated. Main drive
clutch may remain engaged while changing feeds,
making feed changes possible at any time machine is
in operation.
A
rather quick, snappy shift should
be given the feed change handles.
RECTANGULAR
OVERARM
PENDANTS
All Maximillers are equipped with a rectangular over-
arm #42, with fixed dove tail at left side scraped
to perfect alignment with knee and spindle r
accurate and positive alignment at all times,
assur i ng
controlled by the pilot wheel #3, and is locked in
place by two (2) nuts #66 located at right side of
machine. Both nuts should be firmly set up at all
It is
times while machine is in operation.
Pendants #39 and #40 are bored in place on the ma
chine, bushed with bronze bearings and stamped with
the serial number of' the machine. Under no circum
stances should the pendants be interchanged between
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Page 12
machines. Arbor bearings are lubricated from an
oil well in the pendant. A sight oil gauge indi
cates amount of oil in this well at all times.
A 3/8" pipe PIu9 immediately above the gauge is
provided for filling this oil well.
MOUNTING
ARBOR
USE YOUR ARBORS PROPERLY. The utmost care should
be exercised at all times in usfng arbors and
their component parts, including cutters, in order
to achieve the maximum in service and production.
INSIST ON HAVING A STRAIGHT ARBOR. Before insert
ing
an
arbor into a milling machine, clean dirt
or chips from both the arbor shank and the taper
hole in the spindle. Make sure slots in the flange
pass freely over spindle nose keys, and that keys
are firmly seated and held by screws. Hold arbor
in place by hand until threads of draw-in rod are
engaged. Draw arbor to a firm seat in the spindle
with the draw-in rod. Do not pull up too tightly.
To remove arbor, release pull on the draw-in rod
several turns, leaving part of thread in arbor.
Tap end of rod with a soft hammer sufficiently to
release arbor shank from spindle taper.
Hold arbor
in place by hand. Remove rod completely. DO NOT
DROP ARBOR.
Clean faces of all sleeves and bushings to provide
accurate running. Be sure arbor is of ample diam
eter and rigidly supported.
■3
ARBOR KEYS
ARBOR
SUPPORT
Arbors should be equipped with Standard Keys
throughout their entire length (cut in convenient
lengths for ease of insertion). These keys should
be utilized at all times, thus eliminating slip
page at all points of the arbor as well as pre
venting distortion of arbor and wear on faces of
cutters and arbor collars.
Two rigid arbor supports, or pendants #38
are furnished with the machine. Both should be
used whenever possible, especially while heavy
is being done, further supporting them with the
harness #41 if necessary.
If cutter is mounted
#39
work
toward outer end of arbor, intermediate pendant may
be ut i I i zed between the cutter and machine coIumn
thereby preventing tendency of arbor to whip at
,
this point.
See that cutters are sharp,
They should be ground
properly, and run true within .0005"•
- 9 -
Page 13
The arbor must be rigidly supported by the pendant
when tightening arbor nut, otherwise it may be
sprung. The pendant is not required when a very
short stub, or shell end mill type arbor is used.
STORING
ARBORS
MOUNTING
FACE
MILLS
COOLANT
RESERVOIR
Never ram job, or any other part of machine' against
arbor
When not in use, arbors should be stored in a ver
tical rack, suspended by the arbor flange with
front end of arbor free.
veniently located rack, making them readily acces
.
Store arbors in a con
sible and protecting them from injury.
The recess in both face mill and end of spindle
nose should be thoroughly cleaned. Keys should be
firmly held in spindle nose by proper screws. The
cutter should be gently tapped to a seat on spindle
nose and all screws firmly tightened. Before using,
check cutter for run out.
This should never ex
ceed .0005".
The coolant reservoir
machine. To fill
is located in the base of the
reservoir, remove the screen
cover plates at front top of base. Pour coolant at
this point until the level reaches the screens.
The capacity of the reservoirs is as follows:
CLEANING
RESERVOIR
ADJUSTMENTS
For #2 and #3 Maximiller .=■ |2 Gals.
For ft 4 and #5 Max imiIIer e | Q Ga I s
Baffle plates, cast in the reservoir between the
.
'coolant return inlet and pump intake section, pre
vent
chips from being carried back to the pump.
The blocked section may be cleaned by removing the
screen cover plates.
The reservoir can be drained
by removing the |-|./4" pipe plug located at center
on left side of base.
Kempsmith Maximillers are adjusted for alignment,
inspected and operated under heavy test cuts,
before being released for active service. They
require no further adjustments for some time.
Existing adjustments should not be disturbed un-
10 -
Page 14
E
til the necessity for doing so is definitely indi
cated. Whenever adjustments are required, they
should be made by a mechanic who has a thorough
understanding of this type of work. Needless ex
perimentation may prove both harmful and expensive.
CHECKING
ALIGNMENT
CLUTCH
The entire column face of all Maximillers is
scraped true to the spindle, knee and overarm,
and
may be utilized at any point for the purpose of
checking a Iignments
.
To adjust the drive clutch and brake action:
SHUT OFF MOTIVE POWER. Then expose the adjustment
by disconnecting the shift rod #4 on the #2 and #3
Maximiller (or Rod #93 on the #4 and #5 Maximiller)
at the rear end from lever #43 and removing the
three (3) nuts which hold the clutch cover #44 in
place. Cover will then pull off, exposing the
three (3) adjusting screws #1188 with lock nuts
#1189 as shown on planograph drawing of clutch.
Loosen the lock nuts and move screws forward an
equal amount to maintain equal friction bearing.
The clutch spool may be shifted forward to throw
clutch into full engagement before adjusting, when
the screws can all be set up as far as they will
go, automatically giving equal bearing all around.
Brake action is adjusted by screw #1377 and lock
nut #1378. If brake fails to act, back this screw
out
about |/|6", permitting face of spool #3G-2IOD
to contact brake face in cover.
SPINDLE
The front end of all spindles is mounted in two
(2) massive precision RADIAL END THRUST BEARINGS
with rear end mounted in one bearing of the same
type.
These bearings are mounted with FULL PRE
LOAD as specified by the manufacturer, and require
no adjustments for many years.
is required, then proceed as follows:
Be sure adjustment
Remove the
inspection cover #138 on the left side of machine.
Release screws #1355 locking nut #2G-738S just be
hind the large gear at front end of spindle, and
releasing screw #1254 locking inner nut #2G-739S
next to spindle at back end of spindle, as shown
in planograph drawing of spindle assembly. Both
adjusting nuts have right hand threads and are
screwed right hand to tighten.
Extreme care must
be used in setting up these nuts as an excessive
preload will cause bearings to overheat.
I I
Page 15
LEADSCREW
To eliminate excessive backlash in the table lead-
screw #139, (Horizontal travel of table #64) check
the setting of the adjusting nut for the thrust
bearings on the right end of the table.
This nut
should be brought up as tight as possible, by*hand
only, and then locked by the screw provided for
th i s’pur pose
. If backlash is not sufficiently
eliminated, remove bracket #140 from left end gf
table, and move table to the right until bronze
leadscrew compensating nut #2GU-464 in the saddle
is exposed^ Release the two (2) Allen Set-Screws
in bracket *of saddle which locks the bronze nut.
Release screw #1223 locking adjusting nut #3G-4I8AS.
Take up slightly
has right hand thread.
steel nut is required. Lock both nuts in new posi
tion before trying out the leadscrew through the
full range of travel.
on this steel adjusting nut, which
Very little movement of this
If not enough', repeat until
backlash has been eliminated, before installing the
bracket on end of table.
TABLE GIB
The work table #64 on #2 and #4 Maximillers is
equipped with a single taper gib, which is entered
at left end of saddle with the positive stop at the
right end, against which the small end of taper
rests.
The large end of the gib has ample stock
for follow-up adjustment. To adjust this gib re
move gib lock #136, remove gib and file approxi
mately .020" off the thin end of the gib.
Be sure
to keep end of gib square! Reinstall and check.
If necessary, repeat until gib is bearing properly,
and all shake in table has been eliminated.
#3 and
#5 Maximillers are equipped with double gibs, with
the small end of the gibs meeting at the center of
the saddle. For purpose of adjustment: An equal
amount must be faced off both gibs in order that
center point of meeting is maintained.
The adjustable gib lock should be drawn to a firm
seat only at back end of the gib.
If pulled up too
tight, an unnecessary strain is placed on the gib,
creating a high point and causing excessive wear of
the gib.
SADDLE GIB
Saddles on all type Maximillers are equipped with
the same type taper gib, located at right side of
knee, with the positive lock at rear of saddle.
Adjustment of these gibs is identical to the single
table gib described in the preceding paragraph.
12 -
Page 16
KNEE GIB
The Angular Tongued Gib #23, utilized
the knee, requires very little adjustment.
properly fitted at the factory and should require
no adjustment for a long period of time. A small
in
mounting
It is
amount of follow-up is made possible by elongating
the bolt holes in the gib.
ment ever become necessary, remove the gib and
check the 45° angle surface for straightness and
Should further adjust
flatness. Then scrape from the bottom face of the
gib where it bolts to the knee (with a like amount
off the top of the angular tongue), a sufficient
amount to take up the wear. WARNING:
Do not dress
down, or in any way disturb the side walls of the
angular tongue. To do so will throw the entire
front end of the machine out of alignment.
QUICK
TRAVERSE
BELT
FURTHER
ADJUSTMENTS
AND REPAIRS
This is a block type vee belt, running in grooved
sheaves and should not be as tight as a flat belt.
It is made readily accessible for adjustment by re
moval of belt guard #15 at back end of speed box #7.
A lap joint the length of three blocks makes this
an endless belt. Remove the three bolts locking
this joint and if necessary punch extra holes. Be
sure to replace blocks as close to standard spacing
as possible and avoid unnecessary knock in quick
traverse dr i ve .
A reasonable amount of care when operating the
quick traverse control, to avoid throwing these
levers beyond the neutral point with subsequent
sudden reversal of unit, will contribute immeasur
ably to the service life of the quick traverse
drive belt, and the teeth of the drive clutches.
The foregoing suggestions cover all normally re
quired adjustments. For any further adjustments
or repairs The Kempsmith Machine Company will be
pleased to furnish special information or aid on
request. State your difficulty plainly and dis
tinctly,
utilizing
the numbers shown in the back
of this book whenever possible to indicate the
parts involved, and including the serial number of
your machine in all communications.
If necessary,
a picture or planograph showing the parts involved
may be removed from this book and included.
It
will be returned or replaced upon request.
13
Page 17
GENERAL
REMARKS
It is assumed that the prospective user is familiar,
to a certain extent, with current milling machine
practice. Past experience has brought to our atten
tion milling trouble due directly to neglect of
or more of the following points offered at this
one
time, with a view toward aiding the operator in ob
taining maximum results from his Kempsmith Maxi-
mi I I er :
The cutter should always be mounted as close to the
machine column as possible.
Small diameter cutters
wherever permissable, are preferred to larger diam-
eter cutters.
The larger the arbor the better.
The shorter the arbor the better.
All movements not in actual use should be locked
through the clamp handles #29, #60 and #81. This
does not disturb the gib adjustments at all, as the
clamps are independent of the gib.
When changing the position of table or saddle,
that the faces and ways are entirely free from
chips or dirt. Also make sure they are thoroughly
lubricated. Always take backlash out of screws be
see
fore attempting to make an accurate adjustment.
Don't be afraid to use a heavy feed. Kempsmith
Maximillers are all tested under heavy cuts before
shipment. They are intended for heavy duty manufac
turing work. Use a liberal feed, according to the
circumstances of the cut and finish required,
general, milling feeds are entirely too slow, al
I n
though there can be no hard and fast rule as to prop
er
speeds and feeds. A speed and feed chart (See
Pages 24 and 25 of this manual) should aid materi
ally in determining the correct method to employ.
’
v
In general, the proper surface cutting speed depends
on six main condit ions:
I. The nature of the material — If cast iron,
whether it be hard or soft
character of steeI
.
2- The nature of the cut—A slabbing or
—
if steel, what
facing cut can be taken much faster than
either a forming cut, or a deep narrow cut.
3. Method of clamping the wohk—A casting
that can be clamped firmly with cut taken
close to the table, can be more rapidly
machined than a frail casting with a cut
at some distance from proper supports.
4. Sharpness of cutters—The accuracy and
14 -
Page 18
efficiency of all milling machines de
7
pend on sharp and properly ground cutters.
5. Cutters and arbors must run true—Runout
in excess of .001", materially reduces
time between cutter sharpenings.
. 6. Character of the Cutter—We suggest the
use of modern, high-speed steel cutters,
with generous spiral and rake angles,
together with I iberal chip clearance.
The shape of the cutter, as determined
by the cut, is a prime factor.
the feed load per tooth, as high as the
work and machine will permit.
instances carbide tipped cutters can be
utilized to considerable advantage,
especially in the face and slab milling
In many
Maintain
of steel and cast iron.
All machine tools are subject to wear. Your Maxi-
miller is no exception. For efficient and economical
milling
it should be properly maintained, lubricated,
and kept in the best of condition.
Generally speaking, best production is obtained with
heavy feeds and slow speeds. Refer to feed and.
speed chart pages 24 and 25.
15 -
Page 19
maximiller drive requirements
#2 b #3
#2 b ft
#4 b #5
#4 b #5
3
#2
#3
n b #5
#4 & #5
#2 b n
#4
b
#5
#4
#2 b #3
#4 & #5
#2 & #3
#4 & #5
Belt Drive
HorizontaI
VerticaI
HorizontaI
VerticaI
RAMSEY SILENT DRIVE CHAIN
Hor i z
Horiz
Horiz
Horiz
Vert
Vert
Vert
.
5/8 x 2
.
5/8 x 2-1/2
15 H.P. x 3/4 x 3
.
25 H.P. x 3/4 x 4
.
.
.
.
5/8 x 2-1/2
3/4 x 4
15 H.P. x 3/4 x 3
(#B97).
(#BI23)
(# Cl 00)
(#C 128)
LINKS
162
162
140
138
208
I 84
184
Part No.
2BGI03
2BG|
2BG107
02
2BGI08
25181
25183
25185
25186
25182
25780
25184
QUICK TRAVERSE BELT
Horiz
Horiz
Vert
Vert
.
7/8
” x 74"
.
1-1/4"
.
.
7/8" x 102
I -
1/4“x 108"
x
76
”
Cog Vee Belt
“
1949
1950
I 951
I 952
NOTE :
For all #4 Machines After Serial #11301 Use 1-1/4" Belts
NOTE:
For all #4 Machines Previous to Serial #11301 Use 7/8* Belts
#4 & #5
#4
b
#5
PI., Un i v .
VerticaI
b
Horiz
.
7/8
“ x 76
7/8" x 108*
Cog Vee Belt..
”
r
a
a
.3283
...3284
NOTE:
Always add the following for repairs with each of the above belt:
PART
Screws
Nut
Washer
NO. REQUIRED PER BELT
3
3
6
PART NO.
3157
3158
3159
16 -
Page 20
HORIZONTAL PLAIN MAXIMILLER
1
Start & Brake Lever: Horizontal
2
Serial Number
3
Pilot Wheel: Overarm Control
4
Main Drive Clutch Throw
5
Spindle
6
2 Push Button Control Switch
7
Speed Box
8
Speed Change Handles (3)
9
Speed Index Plate
10
Spindle Reverse Handle
11
Main Drive Clutch
12
Pump Drive Shaft and Coupling: Hor. (Upper)
13
Feed Index Plate
14
Feed Box
15
Q. T. Belt Guard
16
Feed Change Handles (3)
17
Feed Box Oil Sight Gauge
18
19
20
21
Crank Assembly
Hand
Pump Drive Shaft and Coupling (Lower)
Pump Drive Clutch
Coolant Pump
17 -
22
Coolant Feed Line
Knee Gib
23
24
Saddle Box: Plain Maxi.
Front Knee Box
25
26
Cross and Vert. Q. T. Control Handle
27
Cross and Vert. Feed Control Handle
28
Table Gib Lock: R. H. End
Knee Lock Handle
29
30
Saddle Cover
Ball Crank Assembly: Cross Feed
31
32
Graduated Dial: Elevating Screw
Graduated Dial: Cross Feed
33
34
Horizontal Q. T. Control Handle
Horizontal Feed Control Handle
35
Positive Table Feed Stops (2)
36
Adjustable Table Feed Stops (5 Asst.)
37
Intermediate Pendant
38
Outer Pendant
39
40
41
Pendant
Harness
Oil Sight /3auge
'
Page 21
HORIZONTAL PLAIN MAXIMILLER
Q. T. Belt Guard: Horizontal
15
Hand Crank Assembly
18
Coolant Pump
21
Rectangular Overarm
42
43
Clutch Throw Lever
Clutch Cover
44
45
Clutch Housing
46
Clutch Support
47
Drive Belt Guard: Horizontal
48
Door: Motor Compartment
49
Knuckle Guard: Feed Box
Stump Nut
50
51
Bronze Telescope Screw
52
Steel Elevating Screw
Slip Shaft and Sleeve: Q. T. Drive
53
54
Slip Shaft and Sleeve: Feed Drive
Knuckle Guard: Rear Knee Box
55
Rear Knee Box
56
57
Knee Lock Rod
Drive Shaft: Q. T.
58
Drive Shaft: Feed
59
Saddle Lock
60
Oil Reservoir: Front End Lubrication
61
Saddle: Plain
62
Graduated Dial: Leadscrew
63
Work Table
64
Eye Bolt: For Lifting Machine
65
18 -
Page 22
HORIZONTAL UNIVERSAL MAXIMILLER
WITH REAR CONTROL
Front Knee Box
25
Rear Knee Box
56
Overarm Lock Nuts (2)
66
Cross and Vert. Feed Flandle: Rear Knee Box
67
Cross and Vert. Q. T. Handle: Rear Knee Box
68
Rear Knee Box Extension: Rear Control
69
Horizontal Feed and Q. T. Lever: Rear Con. Univ.
70
Extension Rod: Q. T. Rear Control
71
Extension Rod: Feed, Rear Control
72
Universal Saddle Box
73
Front Knee Box Extension: Rear Control
74
Cross and Vert. Q. T. Lever: Front Knee Box
75
Cross and Vert. Feed Lever: Front Knee Box
76
Lower Swivel Lock (4 Points)
77
Universal Saddle
78
Upper Swivel Lock (2)
79
Universal Swivel Block
80
Table Lock
81
Directional Feed and Q. T. Lever
82
Positive Table Feed and Q. T. Stops (2)
83
Adjustable Table Feed and Q. T. Stops (2)
84
19
Page 23
VERTICAL MAXIMILLER: RIGID HEAD
Serial Number
2
4
Main Drive Clutch^Throw Rod
Main Drive Clutch
11
Feed Box
14
Hand Crank Assembly
18
Saddle Box: Plain Maxi.
24
Front Knee Box
25
Cross and Vert. Q. T. Control Handle
26
Cross and Vert. Feed Control Handle
27
Knee Lock Handle
29
Ball Crank Assembly: Cross Feed
31
Horizontal Q. T. Control Handle
34
Horizontal Feed Control Handle
35
Positive Table Feed Stop: Plain Maxi. (2)
36
Adjustable Table Feed Stop: Plain Maxi. (5 Asst.)
37
Clutch Throw Lever
43
Knuckle Guard: Feed Box
49
Slip Shaft and Sleeve: Q. T. Drive
53
54
Slip Shaft and Sleeve: Feed Drive
55
Knuckle Guard: Rear Knee Box
56
Rear Knee Box
57
Knee Lock Rod
58
Drive Shaft: Q. T.
59
Drive Shaft: Feed
60
Saddle Lock
Eye Bolt: For Lifting Machine
65
Table Lock
81
Pump Drive Shaft and Coupling: Vert. Upper
85
Flexible Coolant Nozzle
86
Spindle: Vert. Maxi., Rigid Head
87
Inspection Cover: Vertical Head
88
Coolant Control Valve
89
Coolant Line
90
Start and Brake Lever: Vert. Maxi.
91
Front Cover: Vertical Head
92
- 20 -
Page 24
VERTICAL MAXIMILLER: ADJUSTABLE SPINDLE
Serial Number
2
2 Push Button Control Switch
6
Speed Box
7
Speed Change Handles (3)
8
Speed Plate
9
10
Spindle Reverse Handle
16
Feed Change Handles (3)
17
Feed Box Oil Sight Gauge
30
Saddle Cover
32
Graduated Dial: Elevating Screw
Graduated Dial: Cross Feed
33
Clutch Cover
44
Clutch Housing
45
Clutch Support
46
Graduated Dial: Lead Screw
63
64
Work Table
Eye Bolt: For Lifting Machine
65
Upper Horizontal Clutch Throw Rod
93
94
Rear Start and Brake Lever
Rear Clutch Rod Bracket
95
96
Drive Belt Guard: Vertical Maxi:
97
Q. T. Belt Guard: Vertical Maxi.
98
Housing: Clutch Throw Toggle
99
Vertical Clutch Throw Rod
Lower Horizontal Clutch Throw Rod
100
Front Start and Brake Lever
101
Front Bracket: Clutch Throw Rod
102
Spindle: Vertical Adjustable Maxi.
103
Octagonal Quill
104
Spindle Feed Box
105
Directional Feed Lever: Spindle
106
Hand Feed Wheel: Spindle
107
Quill Lock
108
Feed Change Handle: Vert. Spindle
109
Pilot Wheel: Vert. Spindle Control
110
Feed Engaging Clutch: Vert. Spindle
111
Quill Cover: Vert. Spindle
112
Oil Well and Inspection Cover
113
- 21
Page 25
HEAD: VERTICAL MAXIMILLER - ADJUSTABLE SPINDLE
Serial Number
Spindle: Vertical Adjustable Maxi.
Octagonal Quill
Hand Feed Wheel: Spindle
Quill Lock
Pilot Wheel: Vert.. Spindle Control
- 22 -
Feed Engaging Clutch: Vert. Spindle
111
Quill Cover: Vert. Spindle
112
114
Cover: Upper Spindle Bearing
Spring Tension Cover
115
Dial Indicator
116
Adjustable Block: Indicator
117
Page 26
KNEE: CROSS & VERTICAL FEED CONTROL
Coolant Feed Line
Saddle Cover
Horizontal Q. T. Control Handle
Horizontal Feed Control Handle
Positive Table Feed Stop (2)
Adjustable Table Feed Stop (5 Asst.)
Stump Nut
Bronze Telescope Screw
Steel Elevating Screw
Table Lock
Positive Transverse Feed Stop
Cross Feed Screw
Clutch Knob: Power Cross Feed
Clutch Knob: Power Vertical Feed
Elevating Pinion and Shaft
Adjustable Transverse Feed Stop (2)
124
Knee Feed Control Bracket
- 23 -
125
Trip Stud and Pinion: Trans. Feed & Q. T.
126
Trip Rack: Transverse Feed and Q. T.
127
Trip Cam: Transverse Feed and Q. T.
128
Trip Stud and Pinion: Vert, and Q. T. Feed
129
Trip Rack: Vert. Feed and Q. T.
130
131
Knee Cover
Trip Cam: Vert. Feed and Q. T.
Adjustable Vert. Feed Stop (2)
132
Motor Lubricating Cover
133
Positive Vert. Feed Stop (2)
134
Table Gib
135
Table Gib Lock
136
Oil Sight Gauge: Machine Reservoir137
138
139
Inspection Cover
Table Leadscrew
Leadscrew Bracket: L. H. End
140
Page 27
4
SPEED AND FEED CHART
for
NO. 2 and NO. 3 MAXIMILLER
ro
-P*
I
I
Material
To Be
Milled
Altmlmm
Braae
Soft
Bronte
Hard
Bronxe
Very Hard
Caat Iron
Soft
Cas% Iron
Bard
Meet Iron
Chilled
Malleable
Iron
Steel
Soft
Steel
Medina
Steel
Hard
Carbon High 8uper
Tool Speed High
Steel Steel Bpd.Stl.
Cutter Speed In Feet Per Minute
260
To
600
40
To
80
50
To
60
50
To
40
56
To
60
50
To
46
50
To
40
MATERIAL IK CUTTER
ooo
To
1000
70
To
75
66
To
150
60
50
To
To
70
60
60
60
To
To
116
80
40
50
To
To
70
60
50
To
60
80
70
To
To
126
100
70
00
To
To
100
90
60
60
To
To
90
80
50 40
To
60
To
70
Stellite
BOO
To
1600
160
To
260
100
To
160
90
To
150
60
To
90
40
To
60
116
To
160
Tontalvij* Tungsten
Carbide
160
To
260
126
To
200
100
To
160
Carbide
1000
To
2000
560
To
600
200
To
426
126
To
200
260
To
526
160
To
200
100
To
200
260
To
570
Spindle
Speed
RPM
16
21
26
28
36
40
46
56
71
88
120
140
168
192
£21
£60
303
400
.626 | .895 |
• 039
.066
.043
.029
.026
.036
.022
.032.
.018
.026
.022
.016
.014
.020
.011
.016
.013
.009
.007
.010
.006
.007 .0088
.0064
.0042
.0039
.0067 .0080
.0032
.0047
.0028
.0040 .0048
.0026
.0036
.0021
.0027
.0022
.0016
f£ & #3 Maxlalller
Feed—Inohea Per Minute
1.05 I 1.25 1.51 |l.8 1
Feeda—InoheB Per Revolution of Spindle
.070
.066
.060 .124
.042
.038
.030
.026
.023
.019
.015
.012 .084
.0076
.0066
.0066
.0042 .042
.0036
.0026
.094
.060
.072
.050
.061
.046
.054
.036
.043
.031
.038
.028
.034
.023
.027 .033 .038
.021
.018
.014
.017
.010
.013
.0089
.011
.0096
.0066
.0080
.0066 .0067
.0060 .0060
.0041 .0060
.0031 .0038
2.1 |2.6
.128
.112
.006
.100
.072
.084
.064
.075
.051
.060
.052
.046
.040
.047
.025 .029
.020
.024
.018
.015
.013
.015
.011
.013
.0094
.011
.0082
.0096
.0072
.0084
.0060
.0069
.0063
.0045
3,6 1
4.4 |6.27 7.35 8.75 10.6 |l2
.226
.162
.169
.142
.102
.093 .167 .379
.127
.101
.074
.065
.008
.058
.079
.047
.065
.050
.037
.029 .040
.022 .033
.019
.027 .032
.016
.023
.014
.019
.012
.016
.014
.010
.0086 .012
.0066 .009 .011 .016 .018
.391
.274
.297
.210
.260
.176
.224
.126
.179
.110
.156 .184
.139
.098
.114
.080
.062 .008
.050
.071
.052
.037
.045
.028
.039
.023 .033
.020
.020
.026
.017
.016
.021
.467
.350
.295
.263
.210
.164 .194
.134 .160 .192
.102
.061
.052
.047
.030
.033
.029
.024
.662
.547
.504
.417
.424
.350
.312
.250
.308
.218
.266 .310
.236
.124
.149
.121
.100
.073
.088
.076
.062
.066
.067
.046
.055
.048
.039
.036
.040
.029
.022
.027 .037
.6 |l4 .8 1
.787
.600
.600
.450
.360
.281
.229
.178
.142
.105
.090
.079 .094
.066 .077
.057
.050
.042 .061
.032
18.5 25.
.922
1.16 1.56
.880
.706
.692
.740
.628
.660
.422
.529
.371 .464
.328
.411
.268
.536
.208
.260
.190
.210
.124
.154
.132
.106
.117
.096
.084
.067
.059
.074
.049
.046
26856-1
1.19
1.00
.882
.712
.625
.556
.456
.362
.284
.208
.178
.168
.131
.113
.100
.083
.062
Page 28
SPEED AND FEED CHART
f or
NO. 4 and NO. 5' MAXIMILLER
I
ro
CJl
I
i
Material
To Be
Milled
Altzainm
Brea a
Soft
Bronse
Bard
Bronae
Very Hard
Cast Iron
Soft
Caet Iron
Hard
Qtet Iron
Chilled
Malleable
Iron
Steel
Soft
Steel
Medina
Steel
Hard
________________
Carbon High Super
Tool a pood High
Stool Steel Spd.Stl*
Cotter Speed in Feet Per Minute
260
To
600
40
To
80
SO
To
60
50
To
40
56
To
60
SO
To
46
SO
To
40
MATERIAL IK CUTTER
600
To
1000
70
To
76
66
To
ISO
60
SO
To
To
70
60
60
60
To
116
80
40
SO
To
To
70
60
SO
To
60
80
70
To
To
126
100
70
60
To
To
100
90
60
60
To
To
90
80
so
40
To
To
70
60
Stellite
SCO
To
1600
160
To
260
Tnntalim Tungsten
Carbide
100
160
90
ISO
60
To To
90
40
To
60
116
To
160
160
To
260
126
To
200
loo
To
160
Carbide
100 c)
To
2000
560
To
600
200
ToTo
426
126
To
200
260
ToTo To
S26
160
200
100
To
200
260
To
S70
Spindle
Speed
RP1I
14
19
22
26
30
35
40
48
63
78
108
126
141
171
198
226
272
356
#4 & #5 Maximiller
Peed—InohflB Per Minute
.625 I .896 I 1.06 | 1.25 |l.5lll.8 1 2 > 1 I 2.6 '3.6 U.4 I 6.27 17.35 la.76llQ.6 ll£
’
.064
.076
.046
.033 .065
.047
.028
.042
.026
.036
021
.030
.026
018
.022 .031
016
.013
.019
.010
.014
.011
.008
.0083
.0058
.0071 .0084 .010
.006
.0044
.0063
.0037 .0062
.0032
.0046
.0028 . 0040 . 0047 . 0056
.0023 .0033
.0018 .0026 .0030 .0036
.089
.066 .079
.048
.057
.042
.042
.036
.030
.026
.022
.017 .024
.013
.0097 .012 .014
.0076 .009
.0061 .0073
.0053 .0064
.0039 .0046
“
Peede-“Inchoe Per
.128
.108 .447
.069
.050
.060
.050
.043
.036
.038
.032
.026
.020
.016
.019 .046
.012
.011
.0088
.0077
.0067
.0066
.160
.110
.096
.082
.096
.072
.084
.060
.070
.061
.045
.053
.037
.044
.029
.033
.023 .027
.020
.017
.014
.013
.011
.0092
.0080
.0066
Revolution of Spindle
.186
.137
.118
.104
.087
.060 .074
.065
.054 .074
.041
.053
.024
.021
.017
.016
.018
.013
.015
.011
.013
.0093 .012
.0077 .0096 .013
.0042 .0061 .0069 .0073
.257
.314
.232
.190
.200
.164
.144
.176
.147
.120
.126
.101
.090 .110
.092
.067
.070
.056
.041
.038
.029
.036
.026
.031
.021
.026
.022
.018
.020
.016
.016
.012
.010
.626
.330
.386
.334
.284
.294
.250
.208
.245
.178
.210
.156 .266
.184
.130
.153
.099
.127
.081
.094
.058 .068
.050
.059
.044 .052
.043
.037
.032
.037
.028
.053
.023
.027
.021
.018
.767
.626
.558 .975
.460
.483
.598
.424
.350 .505
.292
.354
.302
.250
.219
.221
.181
.168
.138
.112
.136
.081
.098
.069
.085
.062
.075
.062
.061
.054
.044 .064
.039
.047 .066
.032
.039
.030
.026
.6114.8Il8.6l25
.900
1.03
.663
.780
.652
.573
.592
.421
.494
.423
.360
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Page 43
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Page 44
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