Smithy 1220 LTD User Manual

0 (0)

MIDAS 1220 LTD

COMBINATION LATHE/MILL/DRILL

OPERATOR’S MANUAL

Updated July, 2008

170 Aprill Dr., Ann Arbor, MI, USA 48103

Toll Free 1-800-476-4849

www.smithy.com

170 Aprill Dr., Ann Arbor, Michigan, USA 48103

Toll Free Hotline: 1-800-476-4849

Fax: 1-800-431-8892

International: 734-913-6700

International Fax: 734-913-6663

All images shown are from Midas 1220 LTD machine.

without prior written permission of Smithy Co. For information on getting permission for reprints and excerpts, comments, or suggestions, contact info@smithy.com

While every precaution has been taken in the preparation of this manual, Smithy Co. shall not have any liability to any person or entity with respect to any loss or damage caused or alleged to be caused directly or indirectly by the instructions contained in this manual. Please see section on warranty and safety precautions before operating the machine.

Printed and bound in the United States of America.

Table of Contents

Inventory Check List

Items mounted to your machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i

Items packed in the larger Smithy box . . . . . . . . . . . . . . . . . . . . . . . . . .i Items packed in smaller Smity box . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii Items packed in plastic bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

Chapter 1: Introduction

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Chapter 2: Safety

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Chapter 3: Caring For Your Machine

Caring for you machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Chapter 4: Basic Parts of the MI-1220 LTD

Basic Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Chapter 5: Uncrating and Setting Up the MI-1220 LTD

Moving the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Uncrating and Positioning the machine . . . . . . . . . . . . . . . . . . . . . .5-1 Millhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 Tailstock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 Three Jaw Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3 Selecting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3 Cleaning and Lubricating the MI-1220 LTD . . . . . . . . . . . . . . . . . . . .5-4

Oiling the Ways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 Oiling the Millhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 Oiling the Headstock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 Oiling the Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5 Oiling the Compound Angle Toolpost . . . . . . . . . . . . . . . . . .5-5 Oiling the Apron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5 Oiling the Leadscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Oiling the Tailstock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Oiling the Mill/Drill Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

Adjusting Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 Mill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Lathe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 Adjusting Gibs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 Reducing Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Running in the MI-1220 LTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Millhead Run in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Lathe Run in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

Setting Lathe and Mill Speeds for the MI-1220 LTD . . . . . . . . . . .5-10

Chapter 6: Turning

Turing Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Gear Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

Chapter 7: Metal Theory

Tool Sharpness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

Chapter 8: Grinding Cutter Bits for Lathe Tools

High Speed Steel Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1

Materials Other than Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3 Bits for Turning and Machining Brass . . . . . . . . . . . . . . . . . . . . . . . .8-3 Special Chip Craters and Chipbreakers . . . . . . . . . . . . . . . . . . . . . . .8-4 Using a Center Gauge to Check V-Thread Forms . . . . . . . . . . . . . .8-4 Acme or Other Special Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5 Carbide-Tipped Cutters and Cutter Forms . . . . . . . . . . . . . . . . . . . . .8-5

Chapter 9: Setting Up Lathe Tools

Cutting Tool Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1 Turning Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1 Threading Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2 Cutoff, Thread Cutting and Facing Tools . . . . . . . . . . . . . . . . . . . . . .9-3 Boring and Inside Threading Tools . . . . . . . . . . . . . . . . . . . . . . . . . .9-3

Chapter 10: Setting Up with Centers, Collets and Chucks

Centering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1 Mounting Work between Centers . . . . . . . . . . . . . . . . . . . . . . . . . .10-3 Using a Clamp Dog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4 Using Faceplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4 Setting Up Work on Mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-5 Steady Rest and Follow Rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-6

Steady Rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-6 Follow Rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7

Setting Up Work in a Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7 Mounting Work in a Four-Jaw Independent

Lathe Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-8 Mouting Work in a Three-Jaw Universal Chuck . . . . . . .10-9 Toolpost Grinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11

Chapter 11: Lathe Turning

Rough Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

Finish Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2 Turning to Shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2 Machining Square Corners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3 Finishing and Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3 Taper Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-4

Chapter 12: Lathe Facing and Knurling

Facing Across the Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1 Knurling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2

Chapter 13: Cutting Off or Parting with a Lathe

Cutting Off or Parting with a Lathe . . . . . . . . . . . . . . . . . . . . . . . . . .13-1

Chapter 14: Lathe Drilling and Boring

Lathe Drlling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-1

Reaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-1 Boring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-2 Cutting Internal Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-3 Cutting Special Form Internal Threads . . . . . . . . . . . . . . . . . . . . . .14-4

Chapter 15: Changing Gears on Your MI-1220 LTD

Changing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-1

Chapter 16: Cutting Threads on Your MI-1220 LTD

Threading Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1

Cutting Right Hand Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-3 Using the Threading Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-4 Cutting Multiple Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-5 What Not To Do When Cutting Threads . . . . . . . . . . . . . . . . . . . . .16-5 Finishing Off a Threaded End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-5 Cutting Threads on a Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-5

Chapter 17: Milling

Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1

Holding Milling Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-2 Arbors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-2 Collets and Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-2 Adaptors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-3 Milling Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-4 End Mill Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-4 Plain Milling Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-6 Side Milling Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-6 Slitting Saws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-6 Angle Milling Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-7 Form Relieved Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-7 Flycutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-7 Using Cutting Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-8 Tool Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-8 Speeds and Feeds for Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-8 Feeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-9 Up Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-9 Down Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-10 Common Milling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-12

Milling Flat Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-12 Squaring a Workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-12 Milling a Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-13 Tapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-13

Chapter 18: Workholding

Mounting to the Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1 Using a Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1 Dividing Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-2 Rotary Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-2

Chapter 19: Troubleshooting

Powerfeed and Thread Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-1 Carriage and Milling Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-2 Lathe Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-3 Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-4 Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-4 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-5

Chapter 20: Removing the Quill and Quill Feed Assembly

Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-2

Inventory Check List

It is a good idea to take inventory of the parts of your machine soon after it is unpacked. By doing so, you can quickly determine if any parts are missing. In addition, should you find it necessary to return the machine to Smithy for any reason, the inventory will ensure that all the parts you received have been returned. It is also good to take a look at the inventory before you operate the machine so that you can be familiar with the names of all the parts of your Smithy machine.

Items Mounted To Your Machine

The items listed below are shipped mounted on the Smithy Midas 1220 LTD. Kindly check if the following items are present. Use the box before the item as your reference.

Items Mounted To Your

Machine

The items listed below are shipped mounted on the Smithy Midas 1220 LTD. Kindly check if the following items are present. Use the box before the item as

your reference.

5” 3 Jaw Chuck

Part # C30532 Quantity 1

Compound

Angle Toolpost

Part # 45-110 Quantity 1

3/8”

Drawbar

Part # K99-162 Quantity 1

Items Packed in the

Larger Smithy Box

The following items are packed in the larger of the two Smithy boxes.

Air Mask

Part # 15-020 Quantity 1

Protective Goggles

Part # 15-015 Quantity 1

Ear Plugs

Part # 15-025 Quantity 1 Set

i	For Assistance: Call Toll Free 1-800-476-4849

Inventory Checklist

Oil Can

Part # 80-100 Quantity 1

7/16” T-Slot

Nuts

Part # 35-105 Quantity 2

Vise, 0-90º Adjustable Angle

Part # 32-110 Quantity 1

End Mill, 4 FL HSS

1/4” w/3/8” Shank

Part # 50-402 Quantity 1

End Mill, 4 FL HSS

3/8” w/3/8” Shank

Part # 50-406 Quantity 1

End Mill, 4 FL HSS

1/2” w/3/8” Shank

Part # 50-410 Quantity 1

End Mill

Adapter

Part # 65-010 Quantity 1

Lathe Bit Set

Part # 43-000 Quantity 1 Set (AR-8,AL-8,BR-8, BL-8 & E8)

Lathe Chuck Key

Part # C30532 Quantity 1

Drill Chuck,

JT33, 0.8-13 mm with key

(for tailstock)

Part #72-001 Quantity 1

Drill Chuck Arbor,

MT3/JT33

Part # C30523 Quantity 1

Arbor Plug

(M12 x 1.5 x 20 mm setscrew)

Part # S12898 Quantity 1

MT3 Dead Center

Part #41-003 Quantity 1

Or Visit www.smithy.com

Midas 1220 LTD Operator’s Manual

MT4 Dead Center

Part # 41-004 Quantity 1

8/10 mm Open End

Wrench

Part # C30539 Quantity 1

17/19 mm Open End

Wrench

Part # C30535 Quantity 1

Allen Wrench, 4 mm

Part # C30540 Quantity 1

Allen Wrench, 5 mm

Part # C30542 Quantity 1

Allen Wrench, 6 mm

Part # C30537 Quantity 1

Allen Wrench, 8 mm

Part # C30536 Quantity 1

Belts

Part # No Assigned Number Quantity

Items Packed in Smaller

Smithy Box

Outside Jaws for

Lathe Chuck

Part # Quantity 1

Gear,27 Teeth

Part # C30143 Quantity 2

Gear,30 Teeth

Part # C30144 Quantity 1

Gear,32 Teeth

Part # C30145 Quantity 1

Gear,33 Teeth

Part # C30146 Quantity 1

Gear,36 Teeth

Part # C30147 Quantity 1

Gear,66 Teeth

Part # C30148 Quantity 1

Gear,40 Teeth

Part # C30149 Quantity 1

Gear,42 Teeth

Part # C30150 Quantity 1

iii	For Assistance: Call Toll Free 1-800-476-4849

Inventory Checklist

Gear,45 Teeth

Part # C30156 Quantity 1

Gear,48 Teeth

Part # C30151 Quantity 1

Gear,49 Teeth

Part # C30152 Quantity 1

Gear,50 Teeth

Part # C30153 Quantity 1

Gear,56 Teeth

Part # C30157 Quantity 1

Gear,60 Teeth

Part # C30159 Quantity 1

Gear,63 Teeth

Part # C30160 Quantity 1

Gear,70 Teeth

Part # C30202 Quantity 2

Items Packed in Plastic

Bag

DVD, Machine

Tool Basics

Part # 12-003 Quantity 1

Manual Cover

Part # 83-942 Quantity 1

Operator’s Manual

Part # 83-950 Quantity 1

Or Visit www.smithy.com

Midas 1220 LTD Operator’s Manual

Missing Items?

If you find that an item is missing or defective from your Quick Start Tool Pack

Call Us TOLL FREE 1-800-476-4849 or send an e-mail to info@smithy.com

within 30 days of receiving your machine so that we may assist you immediately. Our sales and service technicians are available 8am to 5pm ET, Mondays to Fridays.

v	For Assistance: Call Toll Free 1-800-476-4849

Chapter 1

Introduction

Congratulations on purchasing a Smithy lathe-mill-drill. We are pleased you chose Smithy to fulfill your machining needs.

The purpose of this manual is to give the machinist, beginning or advanced, the information he need to operate the Smithy Midas 1220 LTD. It will teach you about the machine’s parts and how to care for them. We’ll explain how to grind cutters, set up lathe tools, hold work pieces, and do all basic machining operations.

Please read this operator’s manual carefully. If you don’t understand how your machine works, you may damage it, your project, or yourself. If you want to learn more about machining practices, Smithy offers books that meet the needs of machinists at all levels of experience. We also suggest using your local library as a resource. Enrolling in a machining class will give you the best knowledge of machining.

If you have any questions not covered in this manual, please call Smithy. Our trained technicians will help you with any machining problems you may have. Dial our toll free number 1-800-476-4849 Monday through Friday, 8:00 am to 5:00pm Eastern Time. You can also find Smithy on the Internet at www.smithy.com. Check for service updated and service bulletins.

We are always interested in your suggestions to improve our products and services. Feel free to contact us by phone or email us at info@smithy.com. If you have comments about this operator’s manual, or if you have a project you’d like to share with other Smithy owners, contact Smithy Co., PO Box 1517, Ann Arbor, Michigan 48106-1517.

We look forward to a long working relationship with you. Thank you again for putting your trust in Smithy.

This manual should remain with your Smithy machine. If ownership changes, please include the owner’s manual with the machine.

Model No.:__________________________________________________

Serial No.:__________________________________________________

(at the back of the lathe bed)

Purchase Date:______________________________________________

Delivery Date:_______________________________________________

Sales Technician:____________________________________________

Or Visit www.smithy.com

1-1

Chapter 2

Safety

Your workshop is only as safe as you make it. Take responsibility for the safety of all who use or visit it. This list of rules is by no means complete, and remember that common sense is a must.

1.Know your machine. Read this manual thoroughly before attempting to operate your machine. Don’t try to do more than you or your machine can handle. Understand the hazards of operating a machine tool. In particular, remember never to change speeds or set-ups until the machine is completely stopped, and never operate it without first rolling your sleeves or tying them at your wrists.

2.Ground the machine. The MI-1220 LTD has three-conductor cords and three-prong grounding-type receptacles. Never connect the power supply without properly grounding the machine.

3.Remove all adjusting keys and wrenches from the machine before operating. A chuck key or misplaced Allen wrench can be safety hazard.

4.Keep your work area clean and organized. Cluttered work areas and benches invite accidents. Have a place for everything and put everything in place.

5.Keep children away from the machine while it is in use. Childproof your shop with padlocks, master switches, and starter keys, or store the machine where children do not have access to it.

6.Wear appropriate clothing. Avoid loose-fitting clothes, gloves, neckties, or jewelry that could get caught in moving parts. If you have long hairs, tie it up or otherwise keep it from getting into the machine.

7.Use safety glasses, goggles, or a face shield at all times. Use glasses designed for machinery operation; regular glasses will not do. Have extras for visitors. Know when to wear a facemask and earplugs, as well.

8.Check for damaged parts. Make sure the machine will run properly before operating it.

9.Disconnect the machine before servicing and when changing accessories. Shut power off before making changes, removing debris, or measuring your work. Don’t reach over the machine when it’s operating. Keep your hands out of the way.

10.Avoid accidental starts. Turn the switch to OFF before plugging in the machine.

11.Secure your work. Flying metal is dangerous. Loose work can also bind tools.

12.Use the recommended accessories. Understand how to use them before trying them

out.

2-1	For Assistance: Call Toll Free 1-800-476-4849

2: Safety

13.Use the correct tool for the job. Don’t try to make a tool into something it isn’t.

14.Keep your mind on your work. Pay attention to these simple rules and you will spend many safe, enjoyable houses in your workshop.

Note: Your safety depends largely on your practices.

Or Visit www.smithy.com

2-2

Chapter 3

Caring For Your Machine

Your machine is a delicate, precision tool with hardened ways and hand-scraped bearing surfaces under the table and carriage. Any rust spot or battering of the ways, any chips or grit between close-fitting parts, will affect the accuracy of this fine tool. Follow these guidelines whenever you use your Smithy machine:

1.When you finish working, wipe machined surfaces with a clean, oily rag. Never leave the machine without this thin film of protective oil all over parts that might rust, especially ground finished parts.

2.Never lay wrenches, cutting tools, files, or other tools across the ways of your lathe. The slightest dent or burr will impair its accuracy.

3.Before inserting collars, centers, adapters, or drawbar attachments in either the spindle or tailstock spindle, wipe them a clean, oily rag. Also, wipe all internal surfaces carefully with an oily rag on a ramrod. Chips or dirt on the centers or in the spindle nose can scratch or mark surfaces and interfere with the assembled part’s alignment.

4.Lubricate the machine before each use as seen on Section 5.4.

5.Use good 10W 30 weight non-detergent oil on your machine.

6.Cover your machine to protect it from dust and moisture.

Note: An old machinist trick is to leave camphor in the toolbox and on the machine to prevent rust. Newer compounds that also protect machines that will unused for some time are BoeShield, developed by the Boeing Company and CRC Lubricants. There are also specialty oils that may be purchased.

3-1	For Assistance: Call Toll Free 1-800-476-4849

Chapter 4

Basic Parts of the MI-1220 LTD

Learn the operation of your machine, basic units.

you have to know the names and functions of its

	9


			18
3
		4
		4

14 10 11

Figure 4.1 Midas 1220 LTD

1.Bed. The bed is the machine’s foundation. It is heavy, strong, and built for absolute rigidity. The two ways on the top are the tracks on which the carriage and tailstock travel. To maintain an exact relationship between tool point and work piece from one end of the machine to the other, the ways must be absolutely true and accurately aligned to the line of centers and to one other.

2.Carriage. The carriage consists of the saddle and apron. It moves by hand or power along the bed, carrying the cross slide, compound rest, and toolpost. Its function is to support the cutting tool rigidity and move it along the bed for different operations. It locks into place by tightening the carriage lock with the setscrew on the backside of the carriage.

Or Visit www.smithy.com

4-1

Midas 1220 LTD Operator’s Manual

3.Compound Rest. Mounted on the cross slide, the compound rest swivels to any angle horizontal to the lathe axis to produce bevels and tapers. Cutting tools fasten to a toolpost on the compound rest. The calibration on the front of the base are numbered in degrees from 60 right to 60 left.

4.Cross Slide. The T-slotted cross slide moves crosswise 90 degrees to the lathe axis by manual turning of the cross feed screw hand wheel. It also serves as the milling table.

5.Drill Press and Fine Feed Clutch. Pushing in the drill press clutch (engages the fine feed). To work the clutch, release the spring tension by rotating the drill press handles clockwise. Pull the clutch out to sue it as a drill press or push it in to use the fine feed. Use the fine fee hand wheel to move the quill up and down.

6.Forward/OFF/Reverse Switch. This is the main switch used to operate the lathe. It is simply a forward/reverse switch for the motor. The motor turns counterclockwise for normal lathe operation and clockwise for normal milling and drilling operation. The MI-1220 LTD has two switches, one located on the millhead and one on the right side of the gearbox.

7.Gearbox. The gearbox houses the belts that derive the spindle and change gears for the powerfeed. Select the thread pitch (for threading) or the feed rate (for turning) by changing the four change gears on the right side of the gearbox.

8.Headstock. The headstock, which is secured to the bed, houses the gears the drive the powerfeed and the taper that secure the lathe spindle.

9.Lathe Spindle. The end of the lathe spindle facing the tailstock is the spindle nose. The spindle nose, which has an MT4 taper, rotates the work piece and drives the lathe chicks and other workholding devices. All attachments (like three-jaw chucks, four-jaw chucks, faceplates, etc.) bolt to the spindle flange either directly or via an adapter plate.

10.Leadscrew. The leadscrew, which runs the length of the bed, moves the carriage for lathe turning or thread cutting. It works both manually and under power. You can also use it manually with the mill.

11.Locks. Locks on the cross slide, carriage, quill, and tailstock (two) keep them from moving. During machining, lock all axes except the one you want to move.

12.Micrometer Control and Calibration. Just inside the handles of the tailstock crossfeed, drill calibrated in millimeters. The compound feed and crossfeed are calibrated in two thousandths, the tailstock in thousandths, the leadscrew in two thousandths, and the drill press in forty thousandths.

Note: These micrometer dial collars can move independently around the handle shafts. This independent motion is called float. The MI-1220 LTD has floating dials on the cross slide, tailstock, longitudinal and mill feeds. They let you zero the collars at any point and read the feed travel from that point on the dial for increased accuracy.

13. Mill Spindle. The mill spindle attaches to the quill, which moves in and out of the head. The quill lock keeps the quill still when you install or remove tools from it and while milling horizontally. Usually, tools fir into collets that attach through the spindle via drawbars.

4-2	For Assistance: Call Toll Free 1-800-476-4849

4: Basic Parts o thef Midas 1220 LTD

14.Half-nut Lever. This lever transmits power to the carriage for threading.

15.Power Longitudinal Feed. Push the lever down to engage the power of the long feed for general cutting.

16.Power Cross Feed. Push the lever down to engage the cross feed and pull it up to disengage.

17.Powerfeed Speed Selector. The two-speed selector for powering the leadscrew is on the front of the headstock. The leadscrew turns twice as fast in the II position as in the I position.

18.Tailstock. The tailstock, which provides right-end support for the work, moves along the bed and can stop at any point on it. It holds centers, drills, reamers, taps, and other tools. To move the tailstock spindle, which has an MT3 taper, turn the tailstock hand wheel. The scale of offset calibrations on the back of the tailstock is in millimeters.

Note: To offset the tailstock, loosed the four base locking bolts. To offset to the left, loosed the left adjusting bolt and tighten the right and do the same on the other side when you want to offset to the right. See figure. 4.2.

Setover

Screw

Rgiht

Treslte

Setscrew

Figure 4.2 Tailstock base locking bolts.

Or Visit www.smithy.com

4-3

Chapter 5

Uncrating and Setting Up the MI-1220 LTD

Moving the Machine

Moving a machine tool can be dangerous. Improper techniques and methods may injure you and/or damage the machine. To find a professional to move and site your Smithy machine, look in your local Yellow Pages under “Machine Tools, Moving and/or Rigging”. If there is no such listing or your community does not have a rigging specialist, a local machine shop or machinist may be able to provide referral.

When you pick up the machine at the shipping terminal, bring a crowbar, tin snips for cutting the metal straps, and a hammer. If there is obvious shipping damage to the crate, you’ll be able to inspect the machine before signing for it. Note any damage on the bill of lading (shipping document). Fill out the claims forms and notify both Smithy Co. and the shipping terminal about the damage. Failure to notify both parties can complicate and/or invalidate a claims process.

Trucking company terminals usually have forklifts to assist customers. It’s most convenient to transport the machines in trucks without canopies and large vans.

Uncrating and Positioning the Machine

Figure 5.1 Tip the crate from the tailstock end up and over the machine.

The machine is assembled, inspected, and ready to do in its stand. It’s wrapped in a water and greaseproof cover, strongly braced, and crated. A box of accessories is also in the crate.

The metal bands that encircle the crate are under tension. Wearing eye protection and gloves, cut the metal bands with tin snips.

5-1	For Assistance: Call Toll Free 1-800-476-4849

5: Uncrating and Setting Up the MI-1220 LTD

Caution

The cut edges are sharp. The bands secure the crate top to the base.

After removing the straps, lift off the crate top. Tip the crate from the tailstock end up and over the machine (Figure 5.1). Do not damage the crate. You may need it another time to transport the machine.

Once your crate cover is removed it is time to put your machine on its bench. The machine is just less than 500 pounds so make sure you have some extra hands to help. There are four lifting pints that pull out from the bed of the lathe. You can use chains or a tow rope to wraparound these pins and the aid of a lifting device such as an engine hoist to list the machine on to a bench rated to support the machine’s weight.

Without a mechanical device to aid in your lifting you can lighten the machine by removing a few or all of the following:

Millhead

1.Remove the four hexagon socket-head screws at the base of the millhead support column. If a screw runs through the belt box into the flange of the support column, remove it too.

2.Lock the millhead-locking handle.

3.Lift the millhead and column off the lathe head. You may have to rock it back and forth while lifting it. Make sure that the mill head is locked to the column before removing the millhead.

Tailstock

1. Loosen the tailstock lock and pull the tailstock off the end of the bed. The gib and locking pin will fall out. Be careful no to lose them.

Bolts

Figure 5.2 The chuck attaches to the spindle flange with three bolts.

The one bolt located on the other side of the spindle does not show.

Or Visit www.smithy.com

5-2

Midas 1220 LTD Operator’s Manual

Three-Jaw Chuck

1. Remove the three bolts behind the chuck that hold it to the spindle flange (Figure 5.2). The chuck will come off. Don’t let it fall onto the ways. Placing a board between the chuck and ways will protect the ways.

Place the machine on a strong, rigid table 40” long, 24” wide and 28” to 33” high. We recommend you to bolt down the MI-1220 LTD machine using the holes in the base of the bed or using the lifting handles as they held the machine to the shipping pallet.

Selecting a Location

There are several major considerations for selecting a location for your Smithy.

Operation is from the apron side, so allow at least 40” to 48” clearance in front of the machine.

The machine should be on a 20-amp circuit, positioned as close as possible to the power supply. Try not to use an extension cord. If you must use one, check with an electrician about the proper size.

Provide ample working light over the operator’s shoulder.

Figure 5.3 Check along and across the bed to make sure it is level.

Place the machine on a solid foundation, concrete if possible. If you must put it on a wood floor, make sure it is adequate. Brace it if necessary to prevent sagging or settling.

Make allowances at the back of the machine tool as at its end and above it for later additions, attachments, and/or accessories. Provide clearance on the left end for bar stock to be fed through the spindle. If you are considering placing more than one machine in an area, allow enough floor space to feed long bar stock to each machine.

Notice To check bench and bed level accuracies,

successively place level at A, B, C, D (longitudinal positions) and E and F (transverse positions). Bedways alignment in the longitudinal place should be better than 0.0016/40”; alignment in the traverse plane should be better than 0.0024/40”.

5-3	For Assistance: Call Toll Free 1-800-476-4849

5: Uncrating and Setting Up the MI-1220 LTD

Cleaning and Lubricating the MI-1220 LTD

Smithy machines are shipped with protective grease coating called cosmoline. Use WD-40 or non-corrosive kerosene to remove the cosmoline.

Once you have your MI-1220 LTD set up and positioned correctly, you are ready for lubricating. You must do this carefully and thoroughly before starting the machine. Use a pressure oil can and a supply of good quality SAE No.10 weight oil.

To be thorough and complete, follow this routine:

Oiling the Ways

Run the carriage as far to the left as possible. Put a few drops of oil on the ways. Run the carriage to the extreme right and repeat. You may want to use Way Lube, special oil formulated for the ways.

Figure 5.4 Oiling the ways

Oiling the Millhead Quill

Using your mill handles or your fine feed crank to lower the millhead down. Apply a thin layer of oil to the quill and work it down and up until it runs smoothly.

Oiling the Headstock

Figure 5.5 Oiling the

Millhead Quill

Figure 5.6 Oil the button behind the D gear.

Or Visit www.smithy.com

5-4

Midas 1220 LTD Operator’s Manual

Open the gearbox door to expose the pick-off gears. Oil the button in the casting behind the D gear. Then put a few drops of oil on the teeth of all the gears. Grease the zerk on the A gear shaft.

Check the sight glass under the chuck. If necessary, add oil until it is half full. The oil fill plug is at the back of the headstock above the motor. Be careful not to overfill it. The gearbox requires only 8 to 10 ounces of oil.

Oiling the Carriage

Lubricate the oil buttons in the cross feed table. There are two buttons on the left of the saddle for the bedways and two on the front of the cross slide for the cross slide ways.

Oil the button in the center of the cross slide.

Put a few drops of oil on the compound slides.

Figure 5.7 Oiling the table

Oiling the Compound Angle Toolpost

Figure 5.8 Oil the buttons along the cross feed table.

Oil two buttons on top of the compound angle toolpost.

Oiling the Apron

Put oil in the button just behind the cross slide hand wheel.

5-5	For Assistance: Call Toll Free 1-800-476-4849

5: Uncrating and Setting Up the MI-1220 LTD

Put oil on the button at the back of the cross slide.

Oiling the Leadscrew

Put oil in the oil buttons on the left trestle.

Put oil in the support for the right end of the leadscrew.

Oiling the Tailstock

Figure 5.9 Oil the two buttons on the top of the tailstock.

Oil the buttons on top of the tailstock.

Oiling the Mill/Drill Clutch

Figure 5.10 Oil the clutch housing button.

Put oil in the button on top of the clutch housing.

Notice

To keep your machine in peak condition, lubricate it daily after removing any debris. Do not fill the gearbox sight glass more than half way. Too much oil will make the motor lug and sling oil out form behind the chuck and inside the belt box.

Or Visit www.smithy.com

5-6

Midas 1220 LTD Operator’s Manual

Adjusting Belt Tension

The MI-1220 LTD has two belt tensioners installed by the factory. One for the millhead and the other one for the pulley box.

Figure 5.11 Mill belt

Mill

Locate the “L shaped” lever and a thumbscrew at the top of the mill motor. Loosen the thumbscrew and then rotate the lever to increase or decrease the belt tension. Re-tighten the thumbscrew when the desired tension is achieved.

Figure 5.12 Lathe belt tensioner.

Lathe

Locate the belt tensioner handle on the motor mount. To tighten the lathe belts, move the tensioner handle upward so that the handle points toward the lathe head. Turn the knurled knob clockwise to tighten the belt and counterclockwise to loosen it.

Adjusting the Gibs

The MI-1220 LTD machines have straight gibs. Before using the machine, adjust the gibs evenly. First tighten the screws all the way. This will lock the movement. Then loosen each screw one quarter turn and check it. Tighten the gib, the more accurate it will be. Removing and polishing the gibs also improves the tolerances.

With the gibs properly adjusted, review the following instructions on how to reduce the backlash, or lost motion in the screw, which also depends on the type of job you’re doing and/or individual preference.

5-7	For Assistance: Call Toll Free 1-800-476-4849

5: Uncrating and Setting Up the MI-1220 LTD

Reducing Backlash

Backlash of 0.008-0.015” as measured on the dial is normal. If you have more backlash than that in your crossfeed table, refer to the schematics at the back of this manual, if necessary and follow these directions:

1.Tighten the cap nut in the center of the cross feed hand wheel securely.

2.Tighten the set screw inside the T-slot so the brass nut cannot move.

3.Tighten the screw in the base of the brass nut. This will remove play between the threads in the cross feed screw and nut. Do not over tighten it or there will be excess wear on the nut.

If there is still excess backlash, place one or more shim washers between the large shoulder of the cross feed screw and the bush bearing. Ask a Smithy technician about our antibacklash shim washer kit, Item number K99-190.

Figure 5.13 To reduce backlash, tighten the setscrew so the bush bearing will be secured.

To install shims, turn the hand wheel clockwise to move the cross table away from the screw seat. Loosen the setscrew. Then pull out on the hand wheel until the bush bearing is free of the seat. Remove the cap nut, hand wheel, dial, keys, and bush bearing. Install one or more shim washers and reassemble.

Running in the MI-1220 LTD

Though all Smithy machines are run at the factory and again before shipping, it is wise to put your machine through a break-in run before putting it to work. After oiling the machine, check the belts to make sure the tensioners are correct. Do not plug your machine yet. Follow these steps:

Millhead Run-in

1.Make sure that the power switch for the lathe motor and the mill motor are both in the off position.

2.Close the door of the gearbox before starting your machine.

3.Plug the machine into a grounded 20-amp circuit.

Or Visit www.smithy.com

5-8

Midas 1220 LTD Operator’s Manual

4.Start the mill motor by pushing in the green start button. After a few minutes, push in the red stop button and allow the motor to stop. Flip the yellow switch cover and switch it to the opposite position and repeat the above procedure.

5.Start the lathe by pushing the green button on the lathe control panel.

6.Engage the half nut by pushing down the half nut handle, pull up to disengage. Do the same with the cross feed and the longitudinal feeds.

7.Push the lathe stop button and allow the motor to stop. Move the direction selector to the left and flip the yellow cover and switch the red toggle switch to the opposite position and repeat the above procedure.

During the run-in, try all of the controls. Get a feel for your machine before you start to work.

Caution

This machine is equipped with power crossfeed and longitudinal feed.

Caution must be taken to not run the power feeds past their limits of travel. As part of normal operation procedures, run each axis through the entire length of the proposed machining operation before engaging any of the power feeds to assure there is sufficient travel to accomplish the desired task. Failure to do so could result in running one of the power feeds to the end of its mechanical limits. This is what is known as a “CRASH”. A crash can cause damage to the work piece and severe damage to the machine. Remember that becoming familiar with your machine is the best safety insurance you can have.

Lathe Run-in

1.Start the lathe by pushing the green button on the lathe control panel.

2.Engage the half nut by pushing down on the half nut handle, pull up to disengage. Do the same with the cross feed and the longitudinal feeds.

3.Push the lathe stop button and allow the motor to stop. Move the direction selector to the left and flip the yellow reversing switch to the opposite position and repeat the above procedure.

During the run-in, try all of the controls. Get the feel for your machine before you start to work.

5-9	For Assistance: Call Toll Free 1-800-476-4849

5: Uncrating and Setting Up the MI-1220 LTD

Setting Lathe and Mill Speeds for the MI-1220 LTD

LOW

HIGH

C D E

F G H

160

250

400

630

1000

1600

Figure 5.14 Setting Lathe Speeds (RPM)

Changing belts changes lathe speeds. The lower speeds use the two short belts. There is only one position for the motor pulley to idler pulley belt. It goes on the smallest sheave of the motor pulley (behind the largest sheave, Figure 5.14) and on the largest sheave of the idler pulley. For 160 RPM, se the idler pulley to lathe spindle pulley belt on the smallest sheave of the idler pulley to the largest sheave of the spindle pulley (position C). Move it in once sheave for 250 RPM (position D) and one more for 400RPM (position E).

For the higher speeds, remove the two small belts and use the single long belt from the motor pulley to the spindle pulley. For 630 RPM (position F), run the belt from the outside sheave (closest to the door) on the motor pulley. Move it one sheave for 1000 RPM (position G). For 1600 RPM (position H), run it from the largest motor pulley sheave to the smallest spindle pulley sheave.

A4 X B1

315

A3 X B1

630

A2 X B3

1250

A4 X B2

400

A2 X B1

800

A1 X B2

1600

A4 X B3

500

A3 X B2

1000

A1 X B3

2000

Figure 5.15 Setting Mill/Drill Speeds (RPM)

Set mill speeds using various combinations of the mill belts. For 315 RPM, place belt A/B in position 4 and belt B/C in position 1. For 500 RPM, leave belt A/B belt in position 4 and move the B/C belt to position 3.

Or Visit www.smithy.com

5-10

Chapter 6

Turning

The lathe rotates a workpiece against a cutting edge. With its versatility and numerous attachments, accessories, and cutting tools, it can do almost any machining operation.

The modern lathe offers the following:

•The strength to cut hard, tough materials

•The means to hold the cutting point tight

•The means to regulate operating speed

•The means to feed the tool into or across, or into and across, the work, either manually or by engine power, under precise control

•The means to maintain a predetermined ratio between the rates of rotating works and the travel of the cutting point or points.

Turning Speeds

When metal cuts metal at too high a speed, the tool burns up. You can machine soft metals like aluminum at fast speeds without danger or trouble, but you must cut hard steels and other metals slowly.

You must also consider the diameter of the workpiece (Figure 6.1). A point on a 3" diameter shaft will pass the cutting tool three times as fast as a point on a 1 " diameter shaft rotating at the same speed. This is because the point travels a tripled circumference.

For work in any given material, the larger the diameter, the slower the speed in spindle revolutions needed to get the desired feet-per-minute (fpm) cutting speed.

Lathes cut threads in various numbers per inch of material threaded, according to the operator's needs. The MI-1220 LTD cuts metric threads and inch threads standards.

In thread cutting, the carriage carries the thread-cutting tool and moves by rotating the leadscrew . The basic principle is that the revolving leadscrew pulls the carriage in the desired direction at the desired speed. The carriage transports the toolrest and the threading tool, which cuts the screw thread into the metal being machined.

The faster the leadscrew revolves in relation to the spindle, is because the threading tool moves farther across the workpiece revolution.

the coarser the thread. This revolving metal with each

6-1	For Assistance: Call Toll Free 1-800-476-4849

+ 75 hidden pages