Smithy 1220 XL User Manual

MIDAS 1220 XL

COMBINATION LATHE/MILL/DRILL

OPERATOR’S MANUAL

Updated August, 2008

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

Toll Free 1-800-476-4849

www.smithy.com

© 2008 Smithy Co. All rights reserved (Revision 1).

170 Aprill Dr., Ann Arbor, Michigan, USA 48103 Toll Free Hotline: [phone]

Fax: [phone] International: 734-913-6700 International Fax: [phone]

All images shown are from Midas 1220 XL machine.

All rights reserved. No part of this manual may be reproduced or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise,

without prior written permission of Smithy Co. For information on getting permission for reprints and excerpts, comments, or suggestions, contact [e-mail]

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.

Chapter 5: Basic Parts of the MI-1220 XL

Chapter 4: Caring For Your Machine

Chapter 3: Knowing Your Machine

Inventory Check List

Table of Contents

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Chapter 2: Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

. . . . . . . . . . . . . . . . . . . . . . . . .4-1

. . . . . . . . . . . . . . . . . .5-1

Chapter 6: Uncrating and Setting Up the MI-1220 XL

Moving the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Uncrating and Positioning the machine . . . . . . . . . . . . . . . . . . . . . .6-1 Millhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 Tailstock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 Three Jaw Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 Selecting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 Cleaning and Lubricating the MI-1220 LTD . . . . . . . . . . . . . . . . . . . .6-4

Oiling the Headstock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

Oiling the Ways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

Oiling the Carraige . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

Oiling the Tailstock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

Oiling the Apron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

Oiling the Leadscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

Oiling the Compound Angle Toolpost . . . . . . . . . . . . . . . . . .6-7

Setting Up Your MI-1220 XL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

Setting Lathe and Mill Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

Adjusting Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

Adjusting Gibs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

Reducing Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

Crossfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

Longfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

Running in the MI-1220 XL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

Chapter 7: Turning

Turing Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

Gear Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3

Chapter 8: Metalcutting Theory

Tool Sharpness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3

Chapter 9: Grinding Cutter Bits for Lathe Tools

High Speed Steel Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1 Materials Other than Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3 Bits for Turning and Machining Brass . . . . . . . . . . . . . . . . . . . . . . . .9-4 Special Chip Craters and Chipbreakers . . . . . . . . . . . . . . . . . . . . . . .9-4 Using a Center Gauge to Check V-Thread Forms . . . . . . . . . . . . . .9-4 Acme or Other Special Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5 Carbide-Tipped Cutters and Cutter Forms . . . . . . . . . . . . . . . . . . . . .9-5

Chapter 10: Setting Up Lathe Tools

Cutting Tool Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

Turning Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

Threading Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2

Cutoff, Thread Cutting and Facing Tools . . . . . . . . . . . . . . . . . . . . .10-3

Boring and Inside Threading Tools . . . . . . . . . . . . . . . . . . . . . . . . .10-3

Chapter 11: Setting Up with Centers, Collets and Chucks

Centering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1 Centering a Round and Rectangular Steels . . . . . . . . . . . . . . . . . .11-2 Mounting Work between Centers . . . . . . . . . . . . . . . . . . . . . . . . . .11-4 Using a Clamp Dog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-4 Setting Up Work on Mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-6 Steady Rest and Follow Rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-6 Setting Up Work in a Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-8

Mounting Work in a Four-Jaw Independent

Lathe Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-8

Mouting Work in a Three-Jaw Universal Chuck . . . . . .11-10

Collet and Collet Attachements . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-11

Toolpost Grinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-12

Chapter 12: Lathe Turning

Rough Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1 Finish Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2 Turning to Shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2 Machining Square Corners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-3 Taper Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-4 Boring a Tapered Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6

Chapter 13: Lathe Facing and Knurling

Facing Across the Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-1

Knurling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2

Chapter 14: Changing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-1

Chapter 15: Cutting Screw Threads

Threading Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-1 Cutting Right Hand Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-3 Cutting Left Hand Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-4 Cutting Multiple Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-4 What Not To Do When Cutting Threads . . . . . . . . . . . . . . . . . . . . .15-5 Finishing Off a Threaded End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-5 Cutting Threads on a Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-5

Chapter 16: Lathe Drilling and Boring

Reaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1 Boring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-2 Cutting Internal Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-4 Cutting Special Form Internal Threads . . . . . . . . . . . . . . . . . . . . . .16-5

Chapter 17: Cutting Off or Parting with a Lathe . . . . . . . . .17-1

Chapter 18: Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1

Chapter 19: Workholding

Mounting to the Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-1

Using a Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-1

Dividing Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-2

Rotary Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-2

Chapter 20: Holding Milling Cutters

Arbors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1

Collets and Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1

Adaptors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-2

Chapter 21: Milling Cutters

End Mill Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-1

Plain Milling Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-3

Side Milling Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-3

Slitting Saws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-4

Angle Milling Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-4

Form Relieved Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-4

Flycutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-4

Using Cutting Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-5

Tool Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-6

Chapter 22: Speeds and Feeds for Milling

Feeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-1 Up Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-1

Chapter 23: Common Millng Operations

Milling Flat Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23-1

Squaring a Workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23-2

Milling a Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23-2

Tapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23-2

Chapter 24: Common Adjustments

Bevel Gear Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1

Millhead T-Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-2

Chapter 25: Troubleshooting

Powerfeed and Thread Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-1 Carriage and Milling Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-2 Lathe Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-3 Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-4 Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-5 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-6

Chapter 26: MI-1220 XL Full Specifications . . . . . . . . . . . . . . .26-1

Chapter 27: Removing the Apron from the MI-1220 XL 27-1

Chapter 28: Changing the Lateral Drive Shaft in the MI-1220 XL Apron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28-1

Chapter 29: Machine Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29-1

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.

Allen Wrench, 4mm Item #: C30540 Quantity 1

Allen Wrench, 5mm Item #: C30542 Quantity 1

Allen Wrench, 6mm Item #: C30537 Quantity 1

Allen Wrench, 8mm Item #: C30536 Quantity 1

Wrench, 14 mm Item #: 81-500 Quantity 1

Arbor, JT33-MT3 (No Tang)

Item #: C30523 Quantity 1

Drift, MT2

Item #: C30558 Quantity 1

Dead Center, MT3 Item #: 41-003 Quantity 1

Dead Center, MT4 Item #: 41-004 Quantity 1

Drill chuck, 1/2” Item #: 72-001 Quantity 1

Gear, 32 Teeth Item #: C30145 Quantity 2

Gear, 33 Teeth Item #: C30146 Quantity 1

Gear, 39 Teeth Item #: C30148 Quantity 1

Gear, 40 Teeth Item #: C30149 Quantity 1

Or Visit www.smithy.com

i

Midas 1220 XL Operator’s Manual

Gear, 42 Teeth Item #: C30150 Quantity 1

Gear, 45 Teeth Item #: C30156 Quantity 1

Gear, 48 Teeth Item #: C30151 Quantity 1

Gear, 49 Teeth Item #: C30152 Quantity 1

Gear, 50 Teeth Item #: C30153 Quantity 1

Gear, 56 Teeth Item #: C30157 Quantity 1

Gear, 60 Teeth Item #: C30159 Quantity 1

Gear, 70 Teeth Item #: C30202 Quantity 1

Gears on the machine:

	Gear, 27 Teeth
	Item #: C30143
	Quantity 2
	Gear, 30 Teeth
	Item #: C30144
	Quantity 1
	Gear, 60 Teeth
	Item #: C30159
	Quantity 1
ii

Gear, 63 Teeth Item #: C30160 Quantity 1

Jaws (3), 5” Item #: 9-10

Quantity 1 set of 3

Key, Lathe Chuck Item #: C30532 Quantity 1

Key, Drill Chuck Item #: C30533 Quantity 1

Open End Wrench, 8/10mm

Item #: C30539 Quantity 1

Open End Wrench, 17/19mm

Item #: C30535 Quantity 1

Adapter Precision End Mill

Item #: 65-010 Quantity 1

End Mill Single 4 FHSS 3/8 1/4” Item #: 50-402 Quantity 1

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

Inventory Checklist

End Mill Single 4 FHSS 3/8 3/8” Item #: 50-406 Quantity 1

End Mill Single 4 FHSS 3/8 1/4” Item #: 50-410 Quantity 1

T-Slot Nut, 7/16” Item #: 35-105 Quantity 2

Air Mask

Item #: 15-020 Quantity 1

Goggles

Item #: 15-015 Quantity 1

Ear Plug

Item #: 15-025 Quantity 1

Drawbar,

3/8 x 16 x 14” Item #: 75-A Quantity 1

Nut, 3/8 16 Item #: 7-6 Quantity 1

Washer, Flat 5/16” Item #: 7-8 Quantity 1

Washer,

Anti-Back Lash Shim Item #: 82-050 Quantity 3

Vise, Bracket Bolt 3/8 x 1-1/4” Item #: 36-610 Quantity 2

Plug, Drill Chuck Arbor Item #: S12898 Quantity 1

Vise, 0-90 Degrees Adjustable Angle 3-1/4” Jaw Item #: 32-110

Quantity 1

Carbide Bit Set Item #: 43-000 Quantity 1

Machine Tool Basics (DVD) Item #: 12-004 Quantity 1

Cutting Fluid/ Tapping Item #: 49-101 Quantity 1

Or Visit www.smithy.com

iii

Midas 1220 XL Operator’s Manual

Operator’s Manual Item #: 83-949 Quantity 1

Manual Cover Item #: 83-942 Quantity 1

Oil Can

Part # 80-100 Quantity 1

5” 3 Jaw Chuck

Part # C30532 Quantity 1

Compound Angle Toolpost

Part # 45-110 Quantity 1

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 [e-mail]

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.

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

Chapter 1

Introduction

Congratulations on purchasing a Smithy Midas 1220 XL lathe-mill-drill. We are pleased you chose Smithy to fulfil your machining needs.

The purpose of this manual is to give the machinist, beginniner or advanced, the information he needs to operate the Smithy Midas 1220 XL. It will teach you about the machine's parts and how to care for them. In fact, education is our primary goal. We'll explain how to grind cutters, set up lathe tools, hold workpieces, 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 level 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 operator's manual, please call Smithy Co. Our trained technicians will help you with any machining problems you may have. You can reach them by dialing 1-800-476-4849 Monday through Friday, 8:00 am to 5:00 pm Eastern time.

We are always interested in your suggestions to improve our products and services. Feel free to contact us by phone or in writing. 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 the Communications Director, Smithy Co., PO Box 1517, Ann Arbor, MI48106-1517.

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

Customer Information

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

Model # ________________________________________

Serial #_________________________________________

(on 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 remembers that common sense is a must.

Know your machine. Read this manual thoroughly before attempting to operate your lathe1. -mill-drill. 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 setups until the machine is completely stopped, and never to operate it without first rolling up your sleeves or tying them at your wrists.

Ground the machine. The Midas 1220 XL has a three conductor cord and a three pronged2. grounding type receptacle. Never connect the power supply without properly grounding the machine.

Remove all adjusting keys and wrenches from the machine before operating. A chuck key3. or misplaced Allen wrench can be a safety hazard.

Keep your work area clean and organized. Cluttered work areas and benches invite accidents4. . Have a place for everything and put everything in its place.

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

Wear appropriate clothing. Avoid loose fitting clothes, gloves, neckties, or jewellery that6. could get caught in moving parts. If you have long hair, tie it up or otherwise keep it out of the machine.

Use safety glasses, goggles, or a face shield at all times. Use glasses designed for machinery7. operation; regular glasses will not do. Have extras for visitors. Know when to wear a face mask and earplugs, as well.

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

Disconnect the machine before servicing and when changing accessories. Shut power off9. before making changes, removing debris, or measuring your work. Don't reach over the machine when it's operating. Keep you 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.

out12..Use the recommended accessories. Understand how to use them before trying them

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

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 hours in your workshop.

Your safety largely on your practices. Modifying your machine may void the warrantyRemember:and create potential hazards.

Or Visit www.smithy.com

2-2

Chapter 3

Knowing Your Machine

The Midas 1220 XL has a 3/4 hp, 110 V motor. The motor powers the lathe and millhead through the main belt drive and the mill/drill belt drive.

A positive lock clutch in front of the spindle pulley transfers power to either the lathe or the mill. The clutch has three positions. To power the lathe, pull the clutch handle out. To power the mill, push the clutch all the way in. The middle position is neutral. Always shift the clutch with the motor turned off.

The Smithy can use V-belts or round polyurethane belts. The latter produce less dust and is easier to change than standard V-belts.

The lathe runs at six speeds from 160 to 1600 rpm. To change lathe speeds, adjust the belts in the main belt-drive system. This system uses three pulleys: the motor pulley, floating idler pulley and spindle pulley.

To run the lathe at lower turning speeds, use two belts. Install one between the motor and idler pulleys and the other between the idler and spindle pulleys. To increase the speed, move the spindle belt in two more positions on the pulleys.

For higher ranges, use one long belt from the motor pulley directly to the spindle pulley. You can adjust this belt to three different positions on the pulleys.

The millhead also has a belt-drive system. It uses only one belt, adjustable to either the top or bottom position on the pulleys. These two positions, in conjunction with the main belt drive, let you select 12 speeds ranging from 125 to 1600 rpm for milling or drilling.

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Chapter 4

Caring For Your Machine

The Midas 1220 XL is a delicate, precision tool with ground 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.

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

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

Before inserting collars, centers, adapters, or drawbar attachments in either the spindle or tailstock spindle, wipe them with 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 mar surfaces and interfere with the assembled part's alignment.

Lubricate the machine before each use (see Section 6.4)

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Chapter 5

Basic Parts of the MI-1220 XL

To learn the operations of your machine, you have to know the names and functions of its basic parts.

6

19

8

11

10

7

20

4

2 21 17

5

9 1

15 16

Figure 5.1 Basic parts of the MI-1220 XL

Bed - The Bed (Figure 5.1) is the machine's foundation. It is heavy, strong and built for1. absolute rigidity. The two ways on the top are the tracks on which the carriage and tailstock travel. To maintain an exact relationship between toolpoint and workpiece from one end of the machine to the other, the ways must be absolutely true and accurately

5-1aligned to the line of centers and to one another.

Saddle

Cross Slide

Lock

Basic Parts of the MI-1220 XL

Carriage - The carriage consists of the saddle and apron. It moves by hand or power along2. the bed, carrying the cross slides, 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 under the cross slide handwheel.

Change Gears - The change gears cut different thread pitches. They also determine the3. feed rate. Five change gears come installed on the machine; others are packed with it.

Figure 5.2 Your machine arrives with this gear configuration. The C gear, behind B meshes with D. Note the top two gears are permanent.

Compound Rest - Mounted on the cross slide, the compound rest swivels to any angle4. horizontal to the lathe axis to produce bevels and tapers. Cutting tools fasten to a toolpost on the compound rest. The calibrations on the front of the base are numbered in degrees from 60 degree right to 60 degree left.

Cross Slide - The T-slotted cross slide (Figure 5.1 and 5.3) moves crosswise at 90 degree5. to the lathe axis by manual turning of the cross-feed screw hand-wheel. It also serves as the milling table.

Gib Adjustment

Screws

Gib Adjustment

Screw

Cross Slide

Handwheel

Figure 5.3 The cross slide moves laterally when you turn the cross slide handwheel.

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Midas 1220 XL Operator’s Manual

Drill Press and Fine Feed Clutch - Pushing in the drill-press clutch engages the fine feed6. . To work the clutch, release the spring tension by rotating the drill-press handles clockwise. Pull the clutch out to use it as a drill press or push it in to the fine feed. Use the fine-feed handwheel to move the quill up and down.

Forward / Off / Reverse Switch - This is the main switch used to operate the lathe7. . It is simply a forward / reverse switch for the motor. The motor turns counter clockwise for normal lathe operation and clockwise for normal milling and drilling.

Gearbox - The gearbox (Figure 5.1 and 5.4) houses the belts that drive the spindle and8. 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 gear box.

Figure 5.4 The gearbox houses the belts and change gears.

Half-nut Engagement Lever - This lever, located on the apron, transmit power to the9. carriage when rotated 90 degrees to the right.

Half-nut Speed Selector - The two-speed selector for powering the leadsrew is on the10. front of the headstock. The leadscrew turns twice as fast in the II position as in the I position.

Headstock - The headstock, which is secured to the bed, houses the gears that drive the11. powerfeed and the taper bearings that secure the lathe spindle.

Lathe Belt Tensioner - To adjust the lathe belt (Figure 5.5), pull the tensioner handle12. forward to tighten the belt, back to loosen it.

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Basic Parts of the MI-1220 XL

Figure 5.5 To adjust the tension on the lathe belt, move the tensioner handle forward or back.

Lathe / Mill / Drill Clutch - The lathe/mill/drill clutch (Figure 5.4) are inside the gearbox13. . A three-position clutch, it transfers power to either the lathe or the mill, but not to both at the same time. To engage it, rotate it slowly while pushing or pulling on the clutch sleeve. Pulling it to the left runs the lathe, to the right (all the way in) runs the mill/drill. The middle is neutral.

Lathe Spindle - The end of the lathe spindle face in the tailstock is the spindle nose. The14. spindle nose, which has an MT4 taper, rotates the workpiece and drives lathe chucks and other work holding devices. All attachments such as three and four jaw chucks bolt to the spindle flange either directly or via an adapter plate.

Leadscrew - The leadscrew, which runs the length of the bed, moves the carriage for15.lathe turning or thread cutting. It works both manually and under power. You can also use it manually with the mill.

Locks - Locks on the cross slide (Figure 5.3) carriage (Figure 5.1), quill (Figure 5.6), and16. tailstock (two), Figure 5.1 and 5.7, keep them from moving. During machining, lock all lock except the one on the part you want to move.

Figure 5.6 The quill moves in and out of the millhead, carrying the spindle.

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Midas 1220 XL Operator’s Manual

Micrometer Dial Collars - Just inside the handles of the tailstock (Figure5.1), crossfeed17. (Figure 5.1), drill press (Figure 5.1), compound feed (Figure 5.1), and leadscrew (Figure 5.1) there are collars calibrated in inches. The compound feed, leadscrew, and crossfeed are calibrated in two thousandths, the tailstock in thousandths, and the drill press in 40-thousandths.

These micrometer dial collars can move independently around the handle shafts. This independent motion is called float. Floating dials on the cross slide, tailstock, and leadscrew let you zero the collars at any point and read the feed travel from that point on the dial for added accuracy.

Mill Belt Tensioner - To adjust the mill belt (Figure 5.7), swing the roller assembly to18.the front and place the belt on the back of the roller. Loosen the roller assembly and slide it back and forth in its slot.

Figure 5.7 With the millhead cover off, you can adjust the mill-belt tension.

Millhead Height Adjustment - Unlock the mill-head lock and place the height adjustment19. handle in one of the three holes in the black collar. Turn the collar to raise and lower the millhead.

Mill Spindle - The mill spindle (Figure 5.7) attaches to the quill, which moves in and out20. of the head. The quill lock keeps the quill still when you install or remove tools from it and while milling horizontally. Usually, tools fit into collets that attach through the spindle via drawbars.

Tailstock - The tailstock, which provides right-end support for the work, moves along21. the bed and can stop at any point. It has an MT3 taper and holds centers, drills, reamers, taps and other tools. To move the tailstock spindle, turn the tailstock hand wheel.

To offset the tailstock, adjust the two base-locking bolts (Figure 5.8). To offset to the left, loosen the left adjusting bolt and tighten the right. To offset to the right, loosen the right adjusting bolt and tighten the left.

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Basic Parts of the MI-1220 XL

Tailstock Setover

Screw

Tailstock Base-

Locking Bolts

Right Tresle

Setscrew

Figure 5.8 To offset the tailstock, adjust the base-locking bolts.

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5-6

Figure 6.1 Tip the crate from the tailstock end up and over the machine.

Chapter 6

Uncrating and Setting Up The MI-1220 XL

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 to 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 a 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 form 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

The machine is assembled, inspected and ready to go on its stand when you receive it. 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 around the crate are under tension. Wearing eye protection and gloves, cut the metal bands with tin snips. Be carefulthe cut edges are sharp. The band secures 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 6.1). Do not damage the crate; you may need it another time to transport the machine.

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Uncrating and Setting Up the MI-1220 XL

Now open the accessories box. Check the items in it against the accessory checklist. After accounting for all parts, you're ready to move your Midas 1220 XL into its work position.

Four men can move the Midas 1220 XL using the four lifting handles (Figure 5.1). You can reduce the weight so two people can move it by following these instructions:

Millhead

Remove the four hexagon socket-head capscrews at the base of the millhead support column1. (Figure 6.2). If a screw runs through the belt box into the flange of the support column, remove it too.

Figure 6.2 Remove the millhead and column from the lathe head.

2. Lock the millhead locking handle (Figure 5.1)

Lift the millhead and column off the lathe head (Figure 6.2). You may have to rock it back3. and forth while lifting it.

Tailstock

Loosen the tailstock locks (Figure 5.1) and pull the tailstock off the end of the bed. The gib1. and the locking pin will fall out. Be careful not to lose them.

Three-jaw Chuck

Remove the three bolts behind the chuck that hold it to the spindle flange (Figure 6.3). The1. chuck will come off. Place a board between the chuck and ways to protect the ways.

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Midas 1220 XL Operator’s Manual

Bolts

Figure 6.3 The chuck attaches to the spindle flange with three bolts. The one bolt located on the other side of the spindle does not show.

Put the machine on a strong, rigid table 40” long x 24” wide x 28 – 33” high. We recommend you bolt down the machine using the holes in the base of the bed or using the lifting handles the same way they held the machine to the shipping pallet.

Carefully lift the machines by the handles, move it over the stand, and lower it into position. Do not let any part of your body come between the machine and the stand. Bolt the machine to the stand, using one flat washer and one lockwasher per bolt.

Before permanently anchoring the machine, you may want to level the bed (Figure 6.4). The bed is rigid and supports itself, but having a level bed simplifies many setup operations. Use a precision level, both along and across the bed (Figure 6.5). Shim up any low points with sheet metal or other noncompressible material. After tightening the anchor bolts, check the bed again.

Figure 6.4 Check along and across the bed to make sure it is level.

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Uncrating and Setting Up the MI-1220 XL

Figure 6.5 To check bench and bed level accuracies, successively place level at A, B, C, D (longitudinal positions) and E and F (transverse position). Bedways alignment in the longitudinal plane should be better than 0.0016/40” ; alignment in the transverse

plane should be better than 0.0024/40”.

Selecting a Location

There are several major considerations when selecting a location for your Smithy:

Operation is from the apron side, so allow at least 40 – 48” clearance in front of the machine1. .

The machine should be on a 30amp circuit and close to the power outlet. If you must use2. an extension cord, check with an electrician to make sure the cable can handle the electrical load.

3. Provide ample working light over the operator's shoulder.

Place the machine on a solid foundation-concrete, if possible. If the floor is wood, make sur4. e it can support the machine and workbench. Brace it if necessary to prevent sagging or settling.

Make allowances at the back of the machine tool, at the end, and above it for later additions,5. 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.

Cleaning and Lubricating the Machine

Smithy machines are shipped with a protective grease coating. To remove it, spray on WD-40, let it sit for a few minutes, and wipe it off with rags. Use a brush and noncorrosive kerosene or white mineral spirits to clean hard to reach places.

Give special attention to the leadscrew. Use a brush or cotton string to clean down into the threads.

The best way to clean the powerfeed gears is to remove them completely. wipe the pulleys with a damp rag.

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Midas 1220 XL Operator’s Manual

Once it's cleaned, your Smithy is ready for lubricating. Do this carefully and thoroughly before starting the machine. Use pressure oil can and good quality SAE No. 20 or 30 weight machine oil on the bearings and headstock.

To be thorough and complete, follow this routine:

Oiling the Headstock

Open the gearbox door to expose the change gears. Oil the button in the casting behind1. the D gear (Figure 6.6). Then put a few drops of oil on the teeth of all the gears. Grease the zerk on the A gearshaft.

Figure 6.6 Oil the button behind the D gear.

Check the sight glass under the chuck. If necessary, add oil until it is half full. The oil- fi2ll. plug is at the back of the headstock above the motor (Figure 5.5). Be careful no to overfill it. If you have to top it with oil, pour in only an ounce at a time and wait to see the results in the sight glass. Too much oil will make the motor lug and sling oil from behind the chuck and inside the belt box.

Oiling the Ways

Run the carriage as far to the left as possible. Put a few drops of oil on the ways. Run the1. carriage to the extreme right and repeat. You may want to use Way-lube, an oil specially formulated for ways.

Oiling the Carriage

Lubricate the oil buttons in the cross-slide table (Figure 6.7). There are two buttons on the1. front of the cross-slide ways.

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Uncrating and Setting Up the MI-1220 XL

Figure 6.7 Oil the buttons (circled) along the cross-feed table and cross slide.

2.Put a few drops of oil on the compound and cross-slide feedscrews.

3.Put a few drops of oil on the compound slides.

Oiling the Tailstock

1. Oil the buttons on top of the tailstock (Figure 6.8)

Figure 6.8 Oil the two buttons on the top of the tailstock.

Oiling the Apron

1.Put oil in the button just behind the cross-slide handwheel (Figure 6.7).

2.Put oil in the button at the back of the cross-slide (Figure 6.7).

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Midas 1220 XL Operator’s Manual

Oiling the Leadscrew

1.Put oil in the oil buttons in the left trestle.

2.Put oil in the support for the right end of the leadscrew (figure 6.9).

Figure 6.9 Oil the support for the right end of the leadscrew.

3. Put a few drops of oil along the leadscrew and feed shaft.

Oiling the Compound

1. Put oil in the two buttons on the top.

Oiling the Mill/Drill Clutch

1. Put oil in the button on top of the clutch housing (Figure 6.10).

Figure 6.10 Oil the clutch-housing button.

To keep your machine in peak condition, lubricate it daily after removing any debris.

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Uncrating and Setting Up the MI-1220 XL

Setting up Your MI-1220 XL

The Midas 1220 XL comes with all major components assembled, but it is not ready to use right out of the crate. Do not start the motor until you correct the positions of the cross slide and leadscrew handwheels (Figure 5.1). We reversed these handles at our warehouse to protect them during shipment. A drop or two of oil on the shafts will help the handles slide on. Starting the motor with these handles in their shipping positions will damage the machine's gear, bearings, and handles. You must also install the tailstock handwheel, two drill-press handles, millhead lock handle and millhead height adjustment handle.

Setting Lathe and Mill Speeds

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 6.11) and on the largest sheave of the idler pulley. For 160 rpm, set the idler pulley to the 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 one sheave for 250 rpm (position D) and one more for 400 rpm (position E).

LOW

HIGH

C D E

F G H

X

C

160

D

250

E

400

F

630

G

1000

H

1600

Table 6.1Setting Lathe speeds (RPM)

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 to the largest sheave on the spindle pulley. Move it in 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.

Set mill speeds using various combinations of the lathe belts and the belt on top of the millhead. For 125 rpm, place the mill belt in position A and the lathe belts in position C (Figure 6.12). For 160 rpm, place the mill belt in position B and the lathe belts in position C, etc.

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Midas 1220 XL Operator’s Manual

C

A4 X B1

315

A3 X B1

630

A2 X B3

1250

3

2

1

B4

C1

B3

C1

B2

C3

X

B

A4 X B2

400

A2 X B1

800

A1 X B2

1600

4

3

2

1

B4

C2

B2

C1

B1

C2

A

A4 X B3

500

A3 X B2

1000

A1 X B3

2000

4

3

2

1

B4

C3

B3

C2

B1

C3

Table 6.2 Setting Mill/Drill Speeds (RPM)

Adjusting Belt Tension

To get maximum performance from your machine, keep the drive belts snug.

To adjust the tension on the mill belt, swing the roller to the front and place the belt on the back of the roller. Loosen the nut at the bottom of the roller and slide the roller in its shaft to the desired position. Tighten the nut (Figure 5.7).

When you use only the single long belt, the spring at the bottom of the idler-pulley bracket holds the idler pulley so it does not fall onto the motor pulley. To adjust the tension on the spring, loosen the pivot shaft (Figure 6.11) and tighten or loosen the spring as needed. Then retighten the shaft.

Figure 6.11 Adjust the spring tension on the idler-pulley bracket.

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