Southbend SB1027 User Manual

9" X 48" EVS MILLING MACHINE

w/COOLANT SYSTEM & POWER FEED

MODEL SB1027

OWNER'S MANUAL

Hundreds of Thousands of Lathes Sold With a Tradition of Quality Since 1906!

Copyright © April, 2010 For Machines Mfg. Since 8/09

For your convenience, any updates to this manual will be available to download free of charge
through our website at:

www.southbendlathe.com

Scope of Manual

This manual helps the reader understand the machine, how to prepare it for operation, how to control
it during operation, and how to keep it in good working condition. We assume the reader has a basic
understanding of how to operate this type of machine, but that the reader is not familiar with the
controls and adjustments of this specific model. As with all machinery of this nature, learning the
nuances of operation is a process that happens through training and experience. If you are not an
experienced operator of this type of machinery, read through this entire manual, then learn more
from an experienced operator, schooling, or research before attempting operations. Following this
advice will help you avoid serious personal injury and get the best results from your work.

We've made every effort to be accurate when documenting this machine. However, errors sometimes
happen or the machine design changes after the documentation process—so the manual may not
exactly match your machine. If a difference between the manual and machine leaves you in doubt,
contact our customer service (see bottom of page) for clarification.

We highly value customer feedback on our manuals. If you have a moment, please share your
experience using this manual. What did you like about it? Is there anything you would change to
make it better? Did it meet your expectations for clarity, professionalism, and ease-of-use?

South Bend Lathe, Inc.

C

/O Technical Documentation Manager
P.O. Box 2027
Bellingham, WA 98227
Email: [e-mail]

Manual Feedback

Updates

Customer Service

We stand behind our machines. If you have any service questions, parts requests or general questions
about the machine, feel free to contact us.

South Bend Lathe Co.
P.O. Box 2027
Bellingham, WA 98227
Phone: [phone]
Parts Department: [phone]
Fax: [phone] (International)
Fax: [phone] (USA Only)
Email: [e-mail]

Table of Contents

INTRODUCTION

About This Machine .............................................3

Foreword ............................................................. 3

Capabilities .........................................................3

Features .............................................................. 3

Full View Identification ....................................... 4

Drive System, Headstock,

& Control Panel Identification ............................5

Machine Specifications ........................................6

SAFETY

Understanding Risks of Machinery ....................9

Basic Machine Safety ..........................................9

Additional Milling Machine Safety ................... 11

PREPARATION

Preparation Overview ........................................12

Things You'll Need .............................................12

Unpacking ..........................................................13

Inventory ............................................................13

Cleaning & Protecting .......................................14

Location ..............................................................15

Physical Environment ........................................15

Electrical Installation ........................................15

Lighting ............................................................ 15

Weight Load ......................................................15

Space Allocation ................................................ 15

Lifting & Moving ................................................16

Leveling & Mounting ......................................... 17

Leveling ............................................................ 17

Bolting to Concrete Floors ..................................17

Assembly ............................................................18

Ball Handles ......................................................18

Z-Axis Crank ..................................................... 18

Way Covers .....................................................18

Splash Pan & Coolant Return Hoses .................. 19

Initial Lubrication .............................................20

Power Connection .............................................. 20

Test Run ............................................................. 21

Spindle Break-In ................................................24

Inspections & Adjustments ...............................24

OPERATION

Operation Overview ........................................... 25

Control Panel ..................................................... 26

Table Movement.................................................27

Table Locks ....................................................... 27

Graduated Index Rings ...................................... 27

X-Axis Power Feed .............................................28

Head Movement .................................................29

Tilting Head ...................................................... 29

Rotating Head ................................................... 30

Tramming Spindle ............................................. 30

Ram Movement .................................................. 33

Moving Ram Back and Forth..............................33

Rotating Ram .................................................... 33

Setting Spindle Speed ........................................34

Determining Spindle Speed ................................34

Setting Spindle Speed Range .............................34

Setting Spindle Speed ........................................ 35

Downfeed Controls .............................................35

Using the Coarse Downfeed Handle ...................35

Fine Downfeed Controls ..................................... 37

Using the Fine Downfeed Handwheel .................37

Using the Auto-Downfeed System ...................... 38

Spindle Brake .....................................................39

Loading/Unloading Tooling ............................... 40

Loading Tooling ................................................. 40

Unloading Tooling ............................................. 40

MAINTENANCE

Maintenance Schedule .......................................41

Ongoing .............................................................41

Machine Storage ................................................ 41

Before Beginning Operations .............................41

Daily, After Operations ...................................... 41

Cleaning .............................................................43

Unpainted & Machined Surfaces ........................ 43

Lubrication ......................................................... 43

Quill ..................................................................44

Table Ways (One-Shot Oiler) ..............................44

Speed Range Bearing Sleeve .............................. 45

Headstock Gearing ............................................ 45

Ram Ways ......................................................... 45

Head & Ram Rack & Pinion Gear ......................45

Table Elevation Leadscrew ................................46

Power Feed Gears ..............................................46

Coolant Reservoir...............................................48

Checking Coolant Level .....................................48

Changing Coolant .............................................. 49

Machine Storage ................................................ 50

Adjusting Gibs....................................................50

Adjusting Leadscrew Backlash ......................... 51

Longitudinal Leadscrew Backlash ...................... 52

Cross Leadscrew Backlash .................................52

Belt Tensioning ..................................................53

TROUBLESHOOTING .................................................54

ELECTRICAL

Electrical Safety Instructions ...........................56

Upper Electrical Panel ......................................57

Lower Electrical Panel ......................................58

Control Panel Wiring ......................................... 59

Electrical Component Pictures..........................60

PARTS

Headstock ........................................................... 61

Quill ....................................................................64

Gearbox ..............................................................65

Belt Housing.......................................................67

Ram .....................................................................69

Column, Knee & Saddle ....................................70

Table ................................................................... 72

One-Shot Oiler ................................................... 74

Coolant System .................................................. 75

Electric Box & Control Panel ............................76

Tools ....................................................................78

Machine Labels A ..............................................79

Machine Labels B ..............................................80

WARRANTY & RETURNS .......................................... 81

South Bend Vertical Spindle Precision Milling Machine

(circa 1958)

For Machines Mfg. Since 8 /09 Model SB1027

INTRODUCTION

About This Machine

Foreword

"Most boys should learn a trade in order that
they may become skilled workmen. The trained
workman is always in demand...When a boy has
learned a trade, becomes a skilled mechanic,
he has excellent equipment with which to begin
life's battle, but he need not stop there. George
Westinghouse, the Wright Brothers, Henry Ford,
and the Studebaker Brothers were mechanics,
and it was their mechanical training that
made their success possible." —Machine Shop

Equipment, 2nd Ed., 1920, by the O'Brien
Brothers, founders of South Bend Lathe.

The first South Bend milling machine debuted in
the 1950's. During that time, the milling machine
and the already well-established South Bend
lathes created the foundation of many tool rooms
and school shops across America and beyond
her borders. Many young people in those days
came of age on South Bend equipment, becoming
world-class machinists, mechanical engineers,
inventors, and manufacturing visionaries.

A lot has changed in the world since then. Those
same school shops have mostly been replaced
by computer labs. The technology in the rotary
dial phone, television set, mechanical calculator,
computer, and camera of that decade could
barely fit into one large room together—now
they fit into a tiny box that is no bigger than a
box of breath mints. And the average production
machinist spends more time at a computer than
at a machine. Technology has been much refined
and the world operates on a much faster pace.

But some things haven't changed. The same
human ingenuity and passion that created the
best mechanical technology of today still exists
within us. The core machines of the modern shop,
like this South Bend milling machine, are still
fundamentally important.

Capabilities

This Milling Machine is built for daily, non-stop
use in a busy industrial setting, tool room, or
school shop. It is easy to set-up, truly accurate,
and built to give you long years of service when
properly cared for. This milling machine supports
workpieces up to 750 lbs. and is perfect for face
milling, end milling, planing, slot or keyway
cutting, dovetailing, routing, drilling, reaming,
and boring to name a few. With the movable ram
and tilting head, all these tasks can be performed
on horizontal, vertical, and angled surfaces.
When equipped with additional accessories, such
as a rotary table or dividing head, this milling
machine can do even more.

Features

This milling machine features 3-axis table
movement with built-in longitudinal power feed.
It is constructed with high-grade Meehanite
castings, and the saddle and knee ways are
Turcite coated and built with wide dovetails for
maximum support and accuracy through the full
range of movement.

To ensure quality work results, we have equipped
this mill with NSK or NTN spindle bearings that
are rated to P4 (ABEC-7) tolerances. The spindle
taper is R8 and the spindle has powered down
feed with fine, medium, and coarse feed controls.

The headstock is mounted on a wide-dovetail
movable ram with 13" of travel on the column
and 360° rotating capability. The headstock itself
can swivel 90° left/right or 45° forward/back so it
can be positioned for nearly any setup needed.

To reduce the time spent doing daily lubrication,
we have outfitted this milling machine with a
one-shot lubrication system that is as quick and
easy as one pump of a lever.

When you think about it, the greatest mechanical
technology of the future will be what we create
today. As the owner of a South Bend milling
machine, you are now part of a great legacy.
What will you create with yours?

Quality Allen-Bradley electrical components and
attention to detail provide dependable electrical
control of the powered movements.

And finally, this milling machine comes with a
circulating coolant system with the pump and
reservoir in the column base.

-3-

Model SB1027

INTRODUCTION

Full View Identification

For Machines Mfg. Since 8 /09

Drive System & Headstock

(See Page 5

for Identification)

Lifting Eye Bolt

Coolant Nozzle

& Valve

Work Table

X-Axis Ball Handle

Control Panel

(See Page 5

for Identification)

Electrical

Cabinet

Power Feed

Limit Switch

X-Axis

Power Feed

Coolant Return

-4-

Hose

One-Shot

Y-Axis Ball Handle

Knee

Z-Axis Crank

Oiler

Splash Pan

Figure 1. SB1027 full view identification.

For Machines Mfg. Since 8 /09 Model SB1027

INTRODUCTION

Drive System, Headstock, & Control Panel
Identification

Motor

Spindle Brake

& Switch

Manual/Power

Downfeed

Selector

Quill Depth

Downfeed

Rate Selector

Downfeed

Direction Pin

Fine Downfeed

Handwheel

Downfeed Clutch Lever

Adjustable Downfeed Stop

Belt Housing

Stop

Quill

Belt Tension

Adjustment

Lever

Spindle Speed

Display

Emergency

STOP Button

Spindle Speed

Range Selector

ON Button

Coolant Switch

Spindle Direction Switch

Spindle Speed Dial

Coarse Downfeed Lever

Quill Lock Lever

Dial Indicator

Rod

Spindle

Figure 2. SB1027 drive system and headstock identification.

Serious personal injury could occur if
you connect the machine to power before
completing the setup process. DO NOT
connect power until instructed to do so later
in this manual.

Untrained users have an increased risk
of seriously injuring themselves with this
machine. Do not operate this machine until
you have understood this entire manual and
received proper training.

-5-

Model SB1027

Model SB1027

9" x 48" EVS Milling Machine

w/Coolant System & Power Feed

Product Dimensions:

Weight ........................................................................................................................................................................2156 lbs.

Length/Width/Height ................................................................................................................................... 57" x 71" x 87

1

⁄2"

Foot Print (Length/Width) .........................................................................................................................................36" x 24"

Shipping Dimensions:

Type ........................................................................................................................................................................ Wood Crate

Content ........................................................................................................................................................................ Machine

Weight .........................................................................................................................................................................2420 lbs.

Length/Width/Height ....................................................................................................................................... 58" x 54" x 73"

Electrical:

Required Power Source ................................................................................................................ 220V, Single-Phase, 60 Hz

Phase Inverter ................................................................................................................................................Yaskawa V1000

Switch ....................................................................................................... Magnetic Switch w/Thermal Overload Protection

Switch Voltage .................................................................................................................................................................. 220V

Minimum Circuit Size .................................................................................................................................................. 15 Amp

Recommended Power Cord .........................................................................................................14 Gauge, 3 Wire, 300 VAC

Plug Included ........................................................................................................................................................................ No

Recommended Plug ...............................................................................................................................................NEMA 6-15

Motors:

Spindle

Type ...................................................................................................................................................... AEVF Induction

Horsepower .............................................................................................................................................................. 3 HP

Voltage ..................................................................................................................................................................... 220V

Phase .................................................................................................................................................................. 3-Phase

Amps ................................................................................................................................................................. 8.5 Amps

Number Of Speeds .........................................................................................................................................................1

Speeds ............................................................................................................................................................. 1725 RPM

Cycle .......................................................................................................................................................................60 Hz

Power Transfer ............................................................................................................................................... Belt Drive

Bearings ............................................................................................................... Lubricated and Permanently Sealed

P.O. Box 2027, Bellingham, WA 98227 U.S.A.

PHONE: [phone] Ext. 223 • FAX: [phone]

www.southbendlathe.com

Machine Specifications

INTRODUCTION

For Machines Mfg. Since 8 /09

Machine Specifications

-6-

For Machines Mfg. Since 8 /09 Model SB1027

Motors (continued):

Coolant Pump

Type ..............................................................................................................................................TE Induction Class F

Horsepower .............................................................................................................................................................

1

⁄8 HP

Voltage ..................................................................................................................................................................... 220V

Phase .......................................................................................................................................................... Single-Phase

Amps ............................................................................................................................................................... 0.45 Amps

Number Of Speeds .........................................................................................................................................................1

Speeds ............................................................................................................................................................. 3450 RPM

Cycle .......................................................................................................................................................................60 Hz

Power Transfer ............................................................................................................................................ Direct Drive

Bearings ............................................................................................................... Lubricated and Permanently Sealed

Main Specifications:

Operation Information

Spindle Travel .............................................................................................................................................................. 5"

Longitudinal Table Travel ......................................................................................................................................... 30"

Cross Table Travel ..................................................................................................................................................... 12"

Vertical Table Travel ................................................................................................................................................. 16"

Ram Travel ................................................................................................................................................................. 13"

Ram Swivel ............................................................................................................................................................... 180°

Head Tilt..................................................................................................................................... 45° Forward, 45° Back

Head Swivel.......................................................................................................................................90° Right, 90° Left

Distance Range Spindle to Column ..................................................................................................................... 6"–19 "

Distance Range Spindle to Table .........................................................................................................................0"–18 "

Drilling Capacity for Cast Iron ................................................................................................................................... 1"

Drilling Capacity for Steel ........................................................................................................................................3⁄4"

Number of Spindle Speeds ............................................................................................................................... Variable

Range of Spindle Speeds ......................................................................................................................... 60–5000 RPM

Number of Longitudinal Feed Rates ............................................................................................................... Variable

Longitudinal Feed Rate Range .................................................................................................................... 0–3

1

⁄3 FPM

Quill Diameter ...................................................................................................................................................... 3.375"

Number of Quill Auto-Feed Rates ................................................................................................................................3

Quill Auto-Feed Rates .......................................................................................................0.0015, 0.003, 0.006 in./rev.

Table Information

Length/Width/Thickness............................................................................................................................. 48" x 9" x 3"

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

T-Slot Width/Height ............................................................................................................................................

5

⁄8" x 1"

T-Slot Distance Center-to-Center ............................................................................................................................ 2

1

⁄2"

Stud Size ......................................................................................................................................................................

1

⁄2"

Spindle Information

Spindle Taper .............................................................................................................................................................. R8

End Milling Capacity ................................................................................................................................................... 1"

Face Milling Capacity .................................................................................................................................................. 4"

Draw Bar Diameter/TPI ........................................................................................................................................

1

⁄2"-20

Draw Bar Length .................................................................................................................................................... 18

1

⁄2"

Spindle Bearing Type .............................................Angular Contact P4 (ABEC-7) & Double-Shielded Ball Bearing

Spindle Diameter ....................................................................................................................................................1

13

⁄16"

Construction

Quill ......................................................................................................................................................... Chromed Steel

Table ............................................................................................................. Hardened & Precision-Ground Cast Iron

Headstock ...................................................................................................................................... Meehanite Cast Iron

Column & Base ............................................................................................................................. Meehanite Cast Iron

Knee & Saddle............................................................................................................................... Meehanite Cast Iron

Paint .................................................................................................................................................................Urethane

INTRODUCTION

-7-

Model SB1027

Other Specifications

Machine No-Load Sound Level @ 5000 RPM ................................................................................................................ 54 dB

Country of Origin ......................................................................................................................................................... Taiwan

Warranty .........................................................................................................................................................................1 Year

Serial Number Location .......................................................................................Machine ID Label On Column Right Side

Customer Setup & Cleaning Time ......................................................................................................................... 1–2 Hours

Features

High-Quality, Low-Vibration AEVF Spindle Motor
P4 (ABEC-7) High-Quality Angular Contact Spindle Bearings
Powered Recycling Coolant System
X & Y Leadscrew Nuts Double-Bronzed for Ultra-Smooth Movement w/Minimal Backlash
Lever-Action, One-Shot Pump Lubrication System
Auto-Downfeed Stop with Micro-Adjustable Stop
Variable Speed Longitudinal Power Feed
Hardened and Precision-Ground Table Surface
Chromed Steel Quill
Heavy-Duty Spindle Brake

INTRODUCTION

For Machines Mfg. Since 8 /09

-8-

For Machines Mfg. Since 8 /09 Model SB1027

Operating all machinery and machining equipment can be dangerous or relatively safe depending
on how it is installed and maintained, and the operator's experience, common sense, risk awareness,
working conditions, and use of personal protective equipment (safety glasses, respirators, etc.).

The owner of this machinery or equipment is ultimately responsible for its safe use. This
responsibility includes proper installation in a safe environment, personnel training and usage
authorization, regular inspection and maintenance, manual availability and comprehension,
application of safety devices, integrity of cutting tools or accessories, and the usage of approved
personal protective equipment by all operators and bystanders.

The manufacturer of this machinery or equipment will not be held liable for injury or property
damage from negligence, improper training, machine modifications, or misuse. Failure to read,
understand, and follow the manual and safety labels may result in serious personal injury, including
amputation, broken bones, electrocution, or death.

The signals used in this manual to identify hazard levels are defined as follows:

Death or catastrophic
harm WILL occur.

Moderate injury or fire
MAY occur.

Death or catastrophic
harm COULD occur.

Machine or property
damage may occur.

1. Owner’s Manual: All machinery and

machining equipment presents serious
injury hazards to untrained users. To
reduce the risk of injury, anyone who uses
THIS item MUST read and understand
this entire manual before starting.

2. Personal Protective Equipment:

Operating

or servicing this item may expose the user
to flying debris, dust, smoke, dangerous
chemicals, or loud noises. These hazards
can result in eye injury, blindness, long­term respiratory damage, poisoning,
cancer, reproductive harm or hearing loss.
Reduce your risks from these hazards
by wearing approved eye protection,
respirator, gloves, or hearing protection.

3. Trained/Supervised Operators Only:

Untrained users can seriously injure
themselves or bystanders. Only allow
trained and properly supervised personnel
to operate this item. Make sure safe
operation instructions are clearly
understood. If electrically powered, use
padlocks and master switches, and remove
start switch keys to prevent unauthorized
use or accidental starting.

4. Guards/Covers:

Accidental contact with

moving parts during operation may cause
severe entanglement, impact, cutting,
or crushing injuries. Reduce this risk by
keeping any included guards/covers/doors
installed, fully functional, and positioned
for maximum protection.

SAFETY

Understanding Risks of Machinery

Basic Machine Safety

-9-

Model SB1027

5. Entanglement: Loose clothing, gloves,

neckties, jewelry or long hair may
get caught in moving parts, causing
entanglement, amputation, crushing,
or strangulation. Reduce this risk by
removing/securing these items so they
cannot contact moving parts.

6. Mental Alertness: Operating this item

with reduced mental alertness increases
the risk of accidental injury. Do not let a
temporary influence or distraction lead to a
permanent disability! Never operate when
under the influence of drugs/alcohol, when
tired, or otherwise distracted.

7. Safe Environment:

Operating electrically

powered equipment in a wet environment
may result in electrocution; operating near
highly flammable materials may result in a
fire or explosion. Only operate this item in
a dry location that is free from flammable
materials.

8. Electrical Connection: With electically

powered equipment, improper connections
to the power source may result in
electrocution or fire. Always adhere to all
electrical requirements and applicable
codes when connecting to the power source.
Have all work inspected by a qualified
electrician to minimize risk.

9. Disconnect Power: Adjusting or servicing

electrically powered equipment while it
is connected to the power source greatly
increases the risk of injury from accidental
startup. Always disconnect power
BEFORE any service or adjustments,
including changing blades or other tooling.

10. Secure Workpiece/Tooling:

Loose

workpieces, cutting tools, or rotating
spindles can become dangerous projectiles
if not secured or if they hit another object
during operation. Reduce the risk of this
hazard by verifying that all fastening
devices are properly secured and items
attached to spindles have enough clearance
to safely rotate.

11. Chuck Keys or Adjusting Tools:

Tools used

to adjust spindles, chucks, or any moving/
rotating parts will become dangerous
projectiles if left in place when the machine
is started. Reduce this risk by developing
the habit of always removing these tools
immediately after using them.

12. Work Area:

Clutter and dark shadows

increase the risks of accidental injury.
Only operate this item in a clean, non­glaring, and well-lighted work area.

13. Properly Functioning Equipment:

Poorly

maintained, damaged, or malfunctioning
equipment has higher risks of causing
serious personal injury compared to
those that are properly maintained.
To reduce this risk, always maintain
this item to the highest standards and
promptly repair/service a damaged or
malfunctioning component. Always follow
the maintenance instructions included in
this documentation.

14. Unattended Operation:

Electrically

powered equipment that is left unattended
while running cannot be controlled and is
dangerous to bystanders. Always turn the
power OFF before walking away.

15. Cancer or Respiratory Hazards: Certain

cutting fluids and lubricants, or dust/
smoke created when cutting, may
contain chemicals known to cause cancer,
respiratory problems, birth defects,
or other reproductive harm. Minimize
exposure to these chemicals by wearing
approved personal protective equipment
and operating in a well ventilated area.

16. Difficult Operations:

Attempting

difficult operations with which you are
unfamiliar increases the risk of injury.
If you experience difficulties performing
the intended operation, STOP! Seek an
alternative method to accomplish the
same task, ask a qualified expert how the
operation should be performed, or contact
our Technical Support for assistance.

SAFETY

For Machines Mfg. Since 8 /09

-10-

For Machines Mfg. Since 8 /09 Model SB1027

SAFETY

Additional Milling Machine Safety

1. Understanding Controls:

complex machine that presents severe
cutting or amputation hazards if used
incorrectly. Make sure you understand the
use and operation of all controls before you
begin milling.

2. Safety Accessories:

from the cutting operation can cause eye
injury or blindness.

in addition to your safety glasses or use a
face shield when milling.

3. Work Holding:

not properly clamped to the table could cause
the workpiece to fly into the operator with
deadly force! Before starting the machine,
be certain the workpiece has been properly
clamped to the table. NEVER hold the
workpiece by hand during operation.

4. Spindle Speed:

breakage that could send flying debris at
the operator and bystanders, use the correct
spindle speed for the operation. Allow the
mill to gain full speed before beginning the
cut.

5. Spindle Direction Change:

rotation direction while it is spinning could
lead to impact injury from broken tool or
workpiece debris, and workpiece or machine
damage. ALWAYS make sure the spindle is
at a complete stop before changing spindle
direction.

Milling a workpiece that is

To avoid tool or workpiece

The mill is a

Flying chips or debris

Always use a chip guard

Changing spindle

6. Stopping Spindle: To reduce the risk of hand

injuries or entanglement hazards, DO NOT
attempt to stop the spindle with your hand
or a tool. Allow the spindle to stop on its own
or use the spindle brake.

7. Chip Cleanup:

sharp and hot and can cause burns or cuts.
Using compressed air to clear chips could
cause them to fly into your eyes, and may
drive them deep into the working parts of
the machine. Use a brush or vacuum to clear
away chips and debris from the machine or
workpiece and NEVER clear chips while the
spindle is turning.

8. Machine Care & Maintenance:

the mill with excessively worn or damaged
machine parts increases the risk of machine
or workpiece breakage, which could eject
hazardous debris at the operator. Operating
a mill in poor condition will also reduce
the quality of the results. To reduce this
risk, maintain the mill in proper working
condition by ALWAYS promptly performing
routine inspections and maintenance.

9. Cutting Tool Usage:

sharp leading edges—handle them with care!
Using cutting tools that are in good condition
helps to ensure quality milling results and
reduces the risk of personal injury from
broken tool debris. Inspect cutting tools for
sharpness, chips, or cracks before each use,
and ALWAYS make sure the cutting tools
are firmly held in place before starting the
machine.

Chips from the operation are

Operating

Cutting tools have very

-11-

Model SB1027

PREPARATION

For Machines Mfg. Since 8 /09

Preparation Overview Things You'll Need

The purpose of the preparation section is to help
you prepare your machine for operation.

The typical preparation process is as follows:

1. Unpack the machine and inventory the

contents of the box/crate.

2. Clean the machine and its components.

3. Identify an acceptable location for the

machine and move it to that location.

4. Level the machine and either bolt it to the

floor or place it on mounts.

5. Assemble the loose components and make

any necessary adjustments or inspections to
ensure the machine is ready for operation.

6. Connect the machine to the power source.

7. Test run the machine to make sure it

functions properly and is ready for operation.

During the setup process, operation, and
maintenance of your machine, you'll need the
following items:

For Lifting

• Aforkliftorotherpowerliftingdevicerated

for the weight of the machine

• Two sifting straps rated for at least 3000 lbs.
each (refer to Page 16 for details)

For Power Connection

• Aqualifiedelectriciantoensureasafeand

code-compliant connection to the power
source (refer to Page 20 for details)

For Assembly

• Cotton rags

• Mineral spirits

• Safetyglasses

• Oil can with any general machine oil

• Grease gun with any API GL 2 grease

• Stiff grease brush

• Phillips dcrewdriver #2

• Floormounting hardware as needed

• Hex wrench 5mm

• Hex wrench 6mm

• Combo wrench

1

⁄2" or ratchet and 1⁄2" socket

-12-

For Machines Mfg. Since 8 /09 Model SB1027

This item was carefully packaged to prevent
damage during transport. If you discover any
damage, please immediately call Customer
Service at [phone] for advice. You may
need to file a freight claim, so save the containers
and all packing materials for possible inspection
by the carrier or its agent.

PREPARATION

Unpacking

Inventory

After all of the parts, other than the mill, have
been removed from the shipping crate, you
should have the following inventory.

Description (Figure 3) Qty

A. Front Way Cover ............................................1

B. Rear Way Cover .............................................1

C. Fine Downfeed Handwheel............................1

D. Drawbar

E. Ball Handles (Left Y-Axis, X-Axis) ...............2

F. Ball Handle (Power Feed) .............................. 1

G. Ball Handle Handles ...................................... 3

H. Oil Bottle ........................................................ 1

I. Tool Box .......................................................... 1

J. Combo Closed-End Wrench 19/21mm ........... 1

K. Combo Open-End Wrench 12/14mm ............. 1

L. Coarse Downfeed Lever ................................. 1

M. Z-Axis Crank ..................................................1

N. Hex Wrench 10 Pc. Set 1.5–10mm ................ 1

O. Screwdrivers Slotted #2, Phillips #2 ....1 Each

P. Splash Pan ...................................................... 1

Q. Coolant Return Hose Pipe Elbows ................ 2

R. Coolant Return Hoses w/Clamps ..................2

7

⁄16"-20 x 18 1⁄2" .................................. 1

A

D

E

N

C

G

F

H

M

K

O

P

R

Figure 3. Shipping inventory.

B

I

L

J

Q

-13 -

Model SB1027

The unpainted surfaces are coated at the factory
with a heavy-duty rust preventative that
prevents corrosion during shipment and storage.
The benefit of this rust preventative is that it
works very well. The downside is that it can be
time-consuming to thoroughly remove.

Be patient and do a careful job when cleaning
and removing the rust preventative. The time
you spend doing this will reward you with
smooth-sliding parts and a better appreciation
for the proper care of the unpainted surfaces.

Although there are many ways to successfully
remove the rust preventative, we have cleaned
thousands of machines and found the following
process to be the best balance between efficiency
and minimized exposure to toxic fumes or
chemicals.

Before cleaning, gather the following:

• Disposablerags

• Cleaner/degreaser (certain citrus-based

degreasers work extremely well and they
have non-toxic fumes)

• Safetyglasses&disposablegloves

Note: Automotive degreasers, mineral spirits, or

WD•40canbeusedtoremoverustpreventative.

Before using these products, though, test them
on an inconspicuous area of a painted area to
make sure they will not damage it.

Basic steps for removing rust preventative:

1. Put on safety glasses and disposable gloves.

2. Coatallsurfacesthathaverustpreventative

with a liberal amount of your cleaner or
degreaser and let them soak for a few
minutes.

3. Wipe off the surfaces. If your cleaner or

degreaser is effective, the rust preventative
will wipe off easily.

Note: To clean off thick coats of rust preventative

on flat surfaces, such as beds or tables, use

aPLASTICpaintscrapertoscrapeoffthe

majority of the coating before wiping it off

withyourrag.(Donotuseametalscraperor

it may scratch the surface.)

4. Repeat Steps 2–3 as necessary until clean,

then coat all unpainted surfaces with a
quality metal protectant or light oil to
prevent rust.

GAS

Gasoline and petroleum
products have low flash
points and can explode
or cause fire if used for
cleaning. Avoid using these
products to remove rust
preventative.

Many cleaning solvents are
toxic if inhaled. Minimize
your risk by only using
these products in a well
ventilated area.

Avoid chlorine-based solvents, such as
acetone or brake parts cleaner that may
damage painted surfaces. Always follow the
manufacturer’s instructions when using any
type of cleaning product.

PREPARATION

Cleaning & Protecting

For Machines Mfg. Since 8 /09

-14-

For Machines Mfg. Since 8 /09 Model SB1027

= Power connection

63"

36"

24"

38"

831⁄2"

23"

30"

Wall

Wall

30"

Weight Load

Refer to the Machine Specifications for the
weight of your machine. Make sure that the
surface upon which the machine is placed will
bear the weight of the machine, additional
equipment that may be installed on the machine,
and the heaviest workpiece that will be used.
Additionally, consider the weight of the operator
and any dynamic loading that may occur when
operating the machine.

Space Allocation

Consider the largest size of workpiece that will
be processed through this machine and provide
enough space around the machine for adequate
operator material handling or the installation
of auxiliary equipment. With permanent
installations, leave enough space around
the machine to open or remove doors/covers
as required by the maintenance and service
described in this manual.

Physical Environment

The physical environment where your machine
is operated is important for safe operation and
longevity of parts. For best results, operate this
machine in a dry environment that is free from
excessive moisture, hazardous or flammable
chemicals, airborne abrasives, or extreme
conditions. Extreme conditions for this type
of machinery are generally those where the
ambient temperature is outside the range of 41°–
104°F; the relative humidity is outside the range
of 20–95% (non-condensing); or the environment
is subject to vibration, shocks, or bumps.

Electrical Installation

Place this machine near an existing power
source. Make sure all power cords are protected
from traffic, material handling, moisture,
chemicals, or other hazards. Make sure to leave
access to a means of disconnecting the power
source or engaging a lockout/tagout device.

Lighting

Lighting around the machine must be adequate
enough that operations can be performed
safely. Shadows, glare, or strobe effects that
may distract or impede the operator must be
eliminated.

Children or untrained
people may be seriously
injured by this machine.
Only install in an access
restricted location.

PREPARATION

Location

Figure 4. Clearances.

-15 -

Model SB1027

Lifting & Moving

PREPARATION

2. Place the lifting web straps under the ram

and connect them to the safety hook, as
illustrated in Figure 5.

For Machines Mfg. Since 8 /09

This machine and its
parts are heavy! Serious
personal injury may occur
if safe moving methods are
not used. To reduce the
risk of a lifting or dropping
injury, ask others for help
and use power equipment.

The method of lifting and moving the mill
described below requires at least two other
people for assistance, and a forklift with two
lifting web straps rated for at least 3000 lbs.
each.

Important: Before lifting the mill, make sure the
four turret lock bolts (two on either side of the
ram) are torqued to 47 ft/lbs.

To lift and move the mill:

1. Swing the ram around 180° from the position

that it was shipped in, then rotate the
head upright, as illustrated in Figure 5
(refer to Ram Movement on Page 33 and
Headstock Movement on Page 29 for
detailed instructions).

Note: After re-positioning the ram and

headstock, make sure they are locked in
place to prevent unexpected movement
during lifting and moving.

Note: Place padding between the straps and the

mill to protect the ram and ways, and to
keep from cutting the lifting straps.

Lifting

Web Straps

Turret

Lock Bolts

Figure 5. Lifting the mill using web straps.

3. Unbolt the mill from the shipping pallet.

4. With your assistants steadying the load to

keep it from swaying, lift the mill a couple of
inches.

— If the mill tips to one side, lower it to the

ground and adjust the ram or table to
balance the load. Make sure to re-tighten
the lock levers and bolts before lifting the
mill again.

— If the mill lifts evenly, continue to move it

to its permanent location.

-16 -

For Machines Mfg. Since 8 /09 Model SB1027

Leveling machinery helps precision components,
such as bed ways, remain straight and flat
during the lifespan of the machine. Components
on an unleveled machine may slowly twist due to
the dynamic loads placed on the machine during
operation.

To level a machine, place metal shims under
the contact points where the machine rests on
the floor. For best results, use a precision level
that is at least 12" long and sensitive enough to
show a distinct movement when a 0.003" shim
(approximately the thickness of one sheet of
standard newspaper) is placed under one end of
the level. See the figure below for an example of a
high precision level.

We strongly recommend securing your
machine to the floor if it is hardwired to the
power source. Consult with your electrician to
ensure compliance with local codes.

Although not required, we recommend that
you level your machine and mount it to the
floor. Because this is an optional step and floor
materials may vary, mounting hardware is not
included. Generally, you can either bolt your
machine to the floor or mount it on machine
mounts.

PREPARATION

Leveling & Mounting

Leveling

Bolting to Concrete Floors

Anchor

Bolt

Lag Bolt

and Anchor

Figure 7. Common types of fasteners for bolting

machinery to concrete floors.

Figure 6. Example of a precision level.

-17-

Model SB1027

Assembly

PREPARATION

5. Remove the hex nut from the Y-axis

leadscrew.

For Machines Mfg. Since 8 /09

Ball Handles

The ball handles for the X-axis leadscrew have
spring-loaded, keyed center bushings, as shown
in Figure 8. This allows them to disengage
from the leadscrew when using the power feed,
avoiding an entanglement hazard.

Ball Handle

Handle

Spring-Loaded

Bushing

Y-Axis

Ball Handle

Figure 8. Ball handle assemblies.

6. Align the keyway of the ball handle with

leadscrew key, slide the Y-axis ball handle
(see Figure 8) onto the leadscrew, then
secure it in place with the removed hex nut.

7. Thread the handles into the small end of
the ball handles and tighten them with a
wrench.

Z-Axis Crank

Slide the knee crank onto the shaft so that the
teeth of the crank and shaft engage, as shown in
Figure 9.

To install the ball handles:

1. Remove the hex nuts from each end of the

X-axis leadscrew.

2. Identify the two ball handles with the

spring-loaded center bushings (see
Figure 8).

3. For each ball handle, position it so that the

protruding part of the center bushing is
facing toward the table, align the keyway
with the leadscrew key, then slide it onto the
X-axis leadscrew.

4. Secure the ball handles with the hex nuts

removed in Step 1.

Note: Tighten the hex nuts just until they are

snug. Overtightening could increase the
wear of the moving parts.

Z-Axis Crank

Teeth Engaged

Figure 9. Z-axis crank installed.

-18 -

For Machines Mfg. Since 8 /09 Model SB1027

PREPARATION

Way Covers

1. Remove the five button-head cap screws

shown in Figure 10 from the front of the
saddle and knee, position the pleated way
cover in place, then secure it with the
removed cap screws.

Cap Screws

Figure 10. Front way cover installed.

2. Remove the four button-head cap screws

shown in Figure 11 from the column and
the rear of the table, position the rear
way cover in place, then secure it with the
removed cap screws.

Splash Pan & Coolant Return
Hoses

1. Remove the three cap screws shown in

Figure 12 from the base rim, slide the
splash pan into position, then secure it with
the removed cap screws.

Coolant

Return Hoses

Cap

Screw

Screw

Cap

Screw

Figure 12. Splash pan and coolant return hoses

installed.

2. Use Teflon tape or pipe sealant on the

threads of the pipe elbows, then install them
into the coolant drain holes located on both
ends of the table, as shown in Figure 13.

Splash Pan

Cap

Cap

Screws

Figure 11. Rear way cover installed.

Pipe

Elbows

Coolant

Return Screen

Figure 13. Coolant return hose connections.

3. Loosen the hose clamps on the end of the

coolant return hoses, push the hoses onto the
pipe elbows, then re-tighten the clamps.

4. Tug the hoses to make sure they are firmly
attached to the pipe elbow. If they are loose,
repeat Step 3.

-19 -

Model SB1027

5. Loosen the hose clamp screws above the

coolant return screens in the base (see
Figure 13 on the previous page), insert the
hoses so that they will drain into the screens,
then re-tighten the clamp screws to secure
them in place.

6. Install the coarse downfeed lever and the

fine downfeed handwheel, as shown in
Figure 14.

Note: Make sure the pins on the back of

these devices are fully seated in the hubs
before use.

PREPARATION

For Machines Mfg. Since 8 /09

Power Connection

Electrocution or fire
may occur if machine is
ungrounded, incorrectly
connected to power, or
connected to an undersized
circuit. Use a qualified
electrician to ensure a safe
power connection.

Once the machine is set up and assembled as
previously described in this manual, it is ready to
be connected to the power source.

Fine

Downfeed

Handwheel

Coarse

Downfeed

Lever

Figure 14. Coarse downfeed lever and fine downfeed

handwheel installed.

Initial Lubrication

The machine was lubricated at the factory, but
we strongly recommend that you inspect all
lubrication points yourself and provide additional
lubrication if necessary. Refer to Lubrication on
Page 43 for specific details.

Note About Required Power Source: The milling
machine is equipped with a Yaskawa phase
inverter that changes single-phase power into
3-phase which is used by the spindle motor.

Note About Extension Cords: Using an
incorrectly sized extension cord may decrease the
life of electrical components on the machine.

Required Power Source ...........220V, Single-Phase

Full Load Amp Draw ............................ 8.95 Amps

Required Voltage Range ................................ 220V

Frequency ...................................................... 60 Hz

Minimum Circuit Size ............................. 15 Amps

Recommended Power Cord ...14 AWG/3C/300VAC

Recommended Plug/Receptacle .......... NEMA 6-15

Minimum Extension Cord Size ................14 AWG

Maximum Extension Cord Length ................ 50 ft.

To connect the mill to power:

1. Make sure the incoming power source and

the power cord meet the requirements above.

-20-

2. Use the correct size strain relief when you
feed the power cord through the bottom of
the electrical cabinet.

3. Connect the power cord to the terminals as
illustrated in the Electrical Box Wiring
Diagram on Page 58.

For Machines Mfg. Since 8 /09 Model SB1027

PREPARATION

Test Run

Operating the coolant pump of this mill
without the correct amount of coolant in

Pulling the power plug
from the receptacle while
the mill is running could
damage the inverter
inside the electrical box
or other electrical parts.
Always use the emergency
STOP button or the circuit
breaker to turn the mill
OFF before pulling the
plug.

the reservoir could damage it and void the
warranty. ALWAYS make sure there is the
correct amount of coolant in the reservoir
before using the pump.

2. Clean out the coolant reservoir in the base of

the mill, then fill it with coolant (refer to the
Coolant System section on Pages 48–49
for specific details).

3. Clear away all tools and objects used during
assembly and preparation.

After all preparation steps have been completed,
the machine and its safety features must be
tested to ensure correct operation.

If you discover a problem with the operation
of the machine or its safety components, do
not operate it further until you have resolved
the problem. Refer to the Troubleshooting
section on Page 54 for solutions to common
problems that may occur with all mills. If you
need additional help, contact our Tech Support at
[phone].

During the test run, you will verify the proper
operation of the following:

• Spindlemotor

• EmergencySTOPbutton

• Electricalcabinetsafetyswitch

• Spindlebrake

• Coolantpump

• X-axispowerfeed

4. Rotate the spindle speed dial on the control
panel counterclockwise to the lowest setting,
the spindle direction switch to the STOP
(middle) position, and the coolant switch to
the OFF (left) position (see Figure 15). This
will disable these functions for now when the
power initially flows to the control panel in
the next steps.

Spindle

Spindle

Speed Dial

Speed

Display

Spindle

Direction

Switch

Emergency

STOP

Button

To test run the machine:

1. Read and follow the safety instructions at

the beginning of the manual, take required
safety precautions, and make sure the
machine is set up and adjusted properly.

Coolant

Switch

Figure 15. Control panel.

ON

Button

-21-

Model SB1027

PREPARATION

For Machines Mfg. Since 8 /09

5. Set the spindle speed to the low range (refer

to the Setting Spindle Speed Range
section beginning on Page 34 for detailed
instructions).

6. Move the downfeed selector to the manual

(forward) position so that the spindle does
not feed into the table during this test (refer
to the Downfeed Operations section on
Page 35 for detailed instructions).

7. Make sure the electrical cabinet door is

latched shut, then rotate the main power
switch to the ON position so that power
flows to the control panel (see Figure 16).

Main Power Switch

10. Listen for abnormal noises and watch for

unexpected actions from the mill. The
machine should run smoothly and without
excessive vibration or rubbing noises.

— Strange or unusual noises or actions

must be investigated immediately. Press
the emergency STOP button to turn the
machine OFF and disconnect it from
the power source before investigating or
correcting potential problems.

11. Press the emergency STOP button to turn
the machine OFF, then wait for the spindle
to stop on its own.

12. WITHOUT resetting the emergency STOP
button, press the ON button. The machine
should not start.

— If the machine does not start, the

emergency STOP button safety feature is
working correctly.

Figure 16. Location of the main power switch on the

electrical box door.

8. Push the emergency STOP button in, then

twist it clockwise until it pops out. When
the switch pops out, the mill is ready for
operation.

9. Press the ON button to enable power to flow

through the control panel to the spindle
motor, then turn the spindle direction
switch to the forward (right) position to start
spindle motor.

— If the machine does start (with the

emergency STOP button pushed in),
immediately disconnect power to the
machine. The emergency STOP button
safety feature is not working correctly.
This safety feature must work properly
before proceeding with regular operations.
Call Tech Support for help.

13. Reset the emergency STOP button, turn the
main power switch on the electrical cabinet
door to the OFF position, then press the ON
button. Again, the machine should not start.

— If the machine does not start, the main

power switch safety feature is working
correctly.

— If the machine does start (with the main

power switch turned to the OFF position),
immediately disconnect power to the
machine. The main power switch safety
feature is not working correctly. This
safety feature must work properly before
proceeding with regular operations. Call
Tech Support for help.

-22-

For Machines Mfg. Since 8 /09 Model SB1027

PREPARATION

14. Turn the spindle direction switch to the stop

(middle) position to prevent the spindle from
starting when you next use the ON button.

15. Make sure the emergency STOP button has

been reset, press the ON button, then start
spindle rotation.

16. Push the spindle brake lever—the spindle

motor should turn OFF and the spindle
should come to a stop from the pressure of
the brake.

17. Position the coolant nozzle over the table,

turn the coolant switch on the control panel
to the on (right) position to start the coolant
pump, then open the valve at the base of the
nozzle to begin the flow of coolant.

18. Check for leaks from the hose fittings and

that the coolant is properly draining back
into the reservoir through the screen on the
base.

The mill comes with a power feed unit for X-axis
table travel. Proper operation of the limit switch
attached to the front middle of the table is
critical for the safe use of this power feed unit.

If the power feed does not operate as expected
during the following steps, disconnect it
from power and contact our Tech Support at
[phone] for assistance.

To test the X-axis power feed unit and table
limit switch:

1. Make sure all tools, cables, and other items

are well clear of table movement as you
follow these steps.

2. Refer to the Table Movement section,

beginning on Page 27, to understand how
the power feed, table locks, and limit switch
function.

3. Loosen the table locks on the front of the
table.

4. Plug the power feed power cord into a 110V
power outlet.

Note: There are available 110V outlets on the

right side of the electrical cabinet that can
be used for the power feed or other 110V
devices.

5. Make sure the power feed directional lever
is in the neutral (middle) position, turn the
speed dial counterclockwise to the lowest
setting, then flip the power switch to the on
(up) position.

6. Turn the directional lever to the left, slowly
turn the speed dial clockwise to increase the
speed, then confirm that the table is moving
to the left.

7. Watch for the table limit stop to hit the
limit switch and turn the power feed OFF,
stopping the table movement.

8. Turn the directional lever through the
neutral (middle) position and all the way to
the right. The table should begin moving to
the right.

9. Confirm that the table stops moving when
the limit stop presses against the limit
switch plunger.

10. Move the directional lever to the neutral
(middle) position and flip the power switch to
the off (down) position.

Congratulations! The Test Run of the mill is
complete. Continue onto the next page to perform
the Spindle Break-In and Inspections &
Adjustments procedures.

-23-

Model SB1027

PREPARATION

Spindle Break-In

Complete the spindle bearing break-in
procedure to avoid rapid deterioration of
spindle components when the mill is placed
into operation.

The high-quality bearings and gears used in the
mill are manufactured to very close tolerances.
However, this does not guarantee perfect
dimensional mating of the bearing components or
exact meshing of gear teeth. Before operational
stress is placed on these and other moving parts
in the mill, complete this break-in procedure to
conform these components to one another and
ensure trouble-free performance from the mill.

To perform the spindle break-in procedure:

1. Successfully perform all the steps in the

Test Run section beginning on Page 21.

2. Make sure the spindle is at a complete stop.

3. Set the spindle speed to the low range (refer

to Setting Spindle Speed beginning on
Page 34 for detailed instructions).

For Machines Mfg. Since 8 /09

Since the mill head was rotated parallel to
the table for shipping purposes, you will need
to tram the spindle with the table if your first
cut requires a 90° alignment. Refer to the
Tramming Spindle section on Page 30 for
detailed instructions.

Inspections &
Adjustments

The following list of adjustments were performed
at the factory before the machine was shipped:

• Gib Adjustment .................................Page 50

• Leadscrew Backlash

Adjustment .........................................Page 51

Be aware that machine components can shift
during the shipping process. Pay careful
attention to these adjustments during operation
of the machine. If you find that the adjustments
are not set according to the procedures in this
manual or your personal preferences, re-adjust
them.

4. Start the spindle rotation at a medium speed

and let the mill run for 20 minutes.

5. Stop the spindle rotation and allow the

spindle to come to a complete stop by itself.

6. Set the spindle speed to the high range, then

start the spindle rotation at a medium speed
and let the mill run for another 20 minutes.

7. Stop the spindle rotation, and turn the mill

OFF.

The spindle break-in of the mill is now complete!

-24-