Grizzly SB1025F 2 HP 3-Phase Mill Owner's Manual

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Grizzly SB1025F 2 HP 3-Phase Mill Owner's Manual | Manualzz

MODEL SB1025F 9" X 42" MILLING MACHINE w/DRO Manual Insert

PHONE: (360) 734-1540 •

www.southbendlathe.com

The Model SB1025F Milling Machine is the same machine as the Model SB1025 except for the following: • Added a 3-Axis Fagor Digital Readout (DRO).

• Longitudinal table travel reduced to 23 1 ⁄ 2 " due to DRO installation.

Except for the differences noted in this insert, all other content in the Model SB1025 Owner’s Manual applies to this machine. Before operating your new milling machine, you MUST read and understand this insert, the entire Model SB1025 Owner’s Manual, and the Fagor DRO Owner’s Manual to reduce the risk of injury when using this machine.

If you have any further questions about this manual insert or the differences between the Model SB1025F and the Model SB1025, contact our Technical Support at (360) 734-1639 or email [email protected].

New & Changed Parts

1008-1 1008 1111 1008-4 1008-3 1101 1008-2 REF PART # 1008 PSB1026F1008 1008-1 PSB1026F1008-1 1008-2 PSB1026F1008-2 1008-3 PSB1026F1008-3 DESCRIPTION DRO ASSEMBLY FAGOR 3-AXIS DRO DISPLAY FAGOR 30iM DRO X-AXIS SCALE FAGOR MKT-77 DRO Y-AXIS SCALE FAGOR MKT-37 REF PART # 1008-4 PSB1026F1008-4 1101 PSB1025F1101 1111 PSB1025F1111 DESCRIPTION DRO Z-AXIS SCALE FAGOR MKT-47 MACHINE ID LABEL MODEL NUMBER LABEL

Copyright © June, 2011 by South Bend Lathe Co. WARNING: No portion of this manual may be reproduced without written approval. #TS14204 Printed in USA

Model SB1026F

M A N U A L I N S E R T

Mfg. Since 3/11

Product Dimensions Model SB1025F

Mill 9" x 42" with DRO, 3­Phase

Weight........................................................................................................................................................... 1937 lbs.

Width (side-to-side) x Depth (front-to-back) x Height..................................................................... 63 x 58 x 81 in.

Footprint (Length x Width)....................................................................................................................... 36 x 24 in.

Space Required for Full Range of Movement (Width x Depth)......................................................... 81-1/2 x 66 in.

Shipping Dimensions

Type.......................................................................................................................................................... Wood Crate Content.......................................................................................................................................................... Machine Weight........................................................................................................................................................... 2140 lbs.

Length x Width x Height................................................................................................................... 54 x 54 x 73 in.

Electrical

Power Requirement................................................................................................................. 220V, 3-Phase, 60 Hz Prewired Voltage................................................................................................................................................ 220V Full-Load Current Rating...................................................................................................................................... 6A Minimum Circuit Size.......................................................................................................................................... 15A Connection Type..................................................................................................................................... Cord & Plug Power Cord Included.............................................................................................................................................. No Recommended Power Cord............................................................................. “S”-Type, 4-Wire, 14 AWG, 300 VAC Plug Included.......................................................................................................................................................... No Recommended Plug Type.................................................................................................................... NEMA L15-20 Switch Type....................................................................................... Control Panel w/Magnetic Switch Protection Recommended Phase Converter...................................................................................................................... G5844

Motors Main

Horsepower............................................................................................................................................... 2 HP Phase.................................................................................................................................................... 3-Phase Amps..................................................................................................................................................... 6A/5.6A

Speed..................................................................................................................................... 3440 / 1720 RPM Type........................................................................................................................................ AEVF Induction Power Transfer ................................................................................................................................ Belt Drive Bearings.................................................................................................... Sealed & Permanently Lubricated Centrifugal Switch/Contacts Type............................................................................................................. N/A

Model SB1025F

-2-

Page 1 of 3

Mfg. Since 3/11

M A N U A L I N S E R T

Model SB1026F

Main Specifications Operation Info

Spindle Travel............................................................................................................................................ 5 in.

Max Distance Spindle to Column........................................................................................................... 19 in.

Max Distance Spindle to Table............................................................................................................... 18 in.

Longitudinal Table Travel (X-Axis)................................................... 23-1/2 in. (29-1/2 in. w/o Power Feed) Cross Table Travel (Y-Axis).................................................................................................................... 13 in.

Vertical Table Travel (Z-Axis)................................................................................................................. 16 in.

Ram Travel............................................................................................................................................... 13 in.

Turret or Column Swivel (Left /Right)............................................................................................... 360 deg.

Head Tilt (Left/Right)........................................................................................................................... 90 deg.

Head Tilt (Front/Back).......................................................................................................................... 45 deg.

Drilling Capacity for Cast Iron................................................................................................................. 1 in.

Drilling Capacity for Steel...................................................................................................................... 3/4 in.

End Milling Capacity................................................................................................................................. 1 in.

Face Milling Capacity................................................................................................................................ 4 in.

Table Info

Table Length............................................................................................................................................ 42 in.

Table Width................................................................................................................................................ 9 in.

Table Thickness......................................................................................................................................... 3 in.

Number of T-Slots........................................................................................................................................... 3 T-Slot Size............................................................................................................................................... 5/8 in.

T-Slots Centers.................................................................................................................................... 2-1/2 in.

Number of Longitudinal Feeds.......................................................................................................... Variable X-Axis Table Power Feed Rate................................................................................................... 0 – 3.34 FPM X/Y-Axis Travel per Handwheel Revolution..................................................................................... 0.200 in.

Z-Axis Travel per Handwheel Revolution......................................................................................... 0.100 in.

Spindle Info

Spindle Taper.............................................................................................................................................. R-8 Number of Vertical Spindle Speeds............................................................................................................. 16 Range of Vertical Spindle Speeds........................................................................................... 80 – 5600 RPM Quill Diameter.................................................................................................................................... 3.375 in.

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

Drawbar Thread Size............................................................................................................................ 7/16-20 Drawbar Length................................................................................................................................ 18-1/2 in.

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

Construction

Spindle Housing/Quill.................................................................. Chrome-Plated & Precision-Ground Steel Table............................................................................................... Hardened & Precision-Ground Cast Iron Head................................................................................................................................ Meehanite Cast Iron Column/Base................................................................................................................... Meehanite Cast Iron Base.................................................................................................................................................... Cast Iron Paint Type/Finish.............................................................................................................................. Urethane

Other

Country of Origin ........................................................................................................................................... Taiwan Warranty ......................................................................................................................................................... 1 Year Approximate Assembly & Setup Time .......................................................................................................... 1 Hour Serial Number Location ........................................................................................ ID Label on Column Right Side Sound Rating .................................................................................................................................................... 55 dB ISO 9001 Factory ................................................................................................................................................... No Certified by a Nationally Recognized Testing Laboratory (NRTL) .................................................................... No

Model SB1025F Page 2 of 3

-3-

Model SB1026F

M A N U A L I N S E R T Features

Fagor DRO High-Quality, Low-Vibration AEVF Spindle Motor P4 (ABEC-7) High-Quality Angular Contact Spindle Bearings 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 Halogen Work Light Allen-Bradley Electrical Controls Japanese NSK/NTN Bearings Table, Knee and Ram are Equipped with Dual Locking Mechanisms Turcite Coated Ways South Bend Brass Nameplate Meehanite Castings Typical South Bend "No Compromises" Fashion Mfg. Since 3/11

Model SB1025F

-4-

Page 3 of 3

9" X 42" MILLING MACHINE w/POWER FEED

MODEL SB1024 - VARIABLE SPEED, 220V, SINGLE-PHASE MODEL SB1025 - 220V, 3-PHASE MODEL SB1026 - 220V, SINGLE-PHASE

MODEL SB1024 MODEL SB1025

OWNER'S MANUAL

Copyright © March, 2010. Revised March, 2015 (ST) For Machines Mfg. Since 8/09

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.

Manual Feedback

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 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: [email protected]

Updates

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

www.southbendlathe.com

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: (360) 734-1540 Parts Department: (417) 886-2954 Fax: (360) 676-1075 (International) Fax: (360) 734-1639 (USA Only) Email: [email protected]

Table of Contents

INTRODUCTION

About These Machines.........................................3

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

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

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

Front View Identification ....................................4

Model SB1024 Belt Housing & Headstock Identification......................................5

Model SB1025/SB1026 Belt Housing & Headstock Identification......................................6

SB1024 Machine Specifications ..........................7

SB1025 Machine Specifications ..........................9

SB1026 Machine Specifications ........................11

SAFETY

Understanding Risks of Machinery ..................13

Basic Machine Safety ........................................13

Additional Milling Machine Safety ...................15

PREPARATION

Preparation Overview ........................................16

Things You'll Need .............................................16

Unpacking ..........................................................17

Inventory ............................................................17

Cleaning & Protecting .......................................18

Location ..............................................................19

Electrical Installation ........................................19

Lighting Leveling ............................................................19

Weight Load Ball Handles ......................................................19

Space Allocation Using Eye Bolt ................................................19

Physical Environment ........................................19

Lifting & Moving ................................................20

..................................................20

Using Lifting Web Straps Leveling & Mounting .........................................21

............................................................21

Bolting to Concrete Floors ...................................20

..................................21

Assembly ............................................................22

......................................................22

Knee Crank .......................................................22

Way Covers .....................................................23

Power Connection ..............................................24

SB1024 (220V) ...................................................24

SB1025 (220V 3-Phase) ......................................24

SB1026 (220V) ...................................................24

Initial Lubrication .............................................25

Test Run .............................................................25

Spindle Break-In ................................................27

Inspections & Adjustments ...............................27

OPERATION

Operation Overview ...........................................28

Control Panel .....................................................29

Table Movement.................................................29

Graduated Index Rings ......................................30

Table Locks .......................................................30

X-Axis Power Feed .............................................31

Head Movement .................................................32

Tilting Head ......................................................32

Rotating Head ...................................................33

Tramming Spindle .............................................33

Ram Movement ..................................................36

Moving Ram Back-and-Forth .............................36

Rotating Ram ....................................................36

Setting Spindle Speed ........................................37

Determining Spindle Speed ................................37

Setting Spindle Speed Range .............................37

Setting Spindle Speed ........................................41

Downfeed Controls .............................................43

Using the Coarse Downfeed Handle ...................43

Fine Downfeed Controls .....................................45

Using the Fine Downfeed Handwheel .................45

Using the Auto-Downfeed System Loading Tooling Unloading Tooling ......................46

Spindle Brake .....................................................47

Loading/Unloading Tooling ...............................48

.................................................48

.............................................48

MAINTENANCE

Maintenance Schedule .......................................49

Ongoing .............................................................49

Before Beginning Operations .............................49

Daily, After Operations Quill ......................................49

Monthly Maintenance Chart .............................50

Cleaning .............................................................51

Unpainted & Machined Surfaces Lubrication .........................................................51

..................................................................52

Table Ways (One-Shot Oiler) ........................51

..............................52

Speed Range Bearing Sleeve (SB1024 Only) .......53

Headstock Gearing ............................................53

Ram Ways .........................................................54

Head & Ram Rack & Pinion Gear ......................54

Table Elevation Leadscrew ................................54

Power Feed Gears Cleaning Coolant Reservoir...............................56

Hazards ..............................................54

.............................................................56

Cleaning ............................................................56

Machine Storage ................................................57

SERVICE

Adjusting Gibs....................................................58

Adjusting Leadscrew Backlash .........................59

Longitudinal Leadscrew Backlash ......................59

Cross Leadscrew Backlash .................................60

TROUBLESHOOTING ................................................. 61 ELECTRICAL

Electrical Safety Instructions ...........................63

Wiring Overview ................................................64

SB1024/SB1026 Electrical Box .........................65

SB1024/SB1026 Electrical Components ..........66

SB1024/SB1026 Electrical Component Pictures ...............................................................67

SB1025 Electrical Box .......................................68

SB1025 Electrical Components .........................69

SB1025 Electrical Component Pictures ............70

PARTS

Headstock ...........................................................71

Quill ....................................................................74

SB1024 Gearbox .................................................75

SB1025/SB1026 Gearbox ...................................77

SB1024 Belt Housing .........................................79

SB1025/SB1026 Belt Housing ...........................81

Ram .....................................................................83

Column, Knee, & Saddle ...................................85

Table ...................................................................87

One-Shot Oiler ...................................................89

SB1024/SB1026 Electrical Box .........................90

& Control Panel .................................................90

SB1025 Electrical Box & Control Panel ...........91

Accessories .........................................................92

SB1024 Head Machine Labels ..........................93

SB1024 Main Machine Labels ..........................94

SB1025/SB1026 Machine Labels ......................95

WARRANTY & RETURNS .......................................... 97

South Bend Vertical Spindle Precision Milling Machine

(circa 1958)

For Machines Mfg. Since 8/09

I N T R O D U C T I O N

SB1024/SB1025/SB1026

About These Machines

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.

Capabilities

These Milling Machines are built for daily, non-stop use in a busy industrial setting, tool room, or school shop. They are easy to set-up, truly accurate, and built to give you long years of service when properly cared for. These milling machines support workpieces up to 750 lbs. and are 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, these milling machines can do even more.

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 men in those days came of age on South Bend equipment, becoming world-class machinists, mechanical engineers, inventors, and manufacturing visionaries.

Features

These milling machines feature 3-axis table movement with built-in longitudinal power feed. They are 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.

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.

To ensure quality work results, we have equipped these mills with NSK or NTN spindle bearings that are rated to P4 (ABEC 7) tolerances. The spindle tapers are R8 and the spindles have powered down feed with fine, medium, and coarse feed controls.

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

To reduce the time spent doing daily lubrication, we have outfitted these milling machines 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?

And finally, each machine is designed to accept a circulating coolant system with room for the pump and reservoir in the column base. Additional features include a movable work light, and Allen Bradley electrical controls.

-3-

SB1024/SB1025/SB1026

I N T R O D U C T I O N

Front View Identification

For Machines Mfg. Since 8/09

Motor Belt Housing (see Pages 5–6) Spindle Brake Halogen Work Light Left X-Axis Ball Handle Headstock (see Pages 5–6) Ram Controls Slotted Work Table Right X-Axis Ball Handle Power Feed Limit Switch Knee Crank One-Shot Oiler Mounting Points (1 of 4) Control Panel Y-Axis Ball Handle Knee Figure 1. Identification—front view (Model SB1024 shown).

X-Axis Power Feed Electrical Cabinet

-4-

For Machines Mfg. Since 8/09

I N T R O D U C T I O N

Model SB1024 Belt Housing & Headstock Identification

SB1024/SB1025/SB1026

Motor Assembly Low Range Variable Speed Indicator High Range Variable Speed Indicator Spindle Brake Variable Speed Handwheel Auto-Downfeed Rate Selector Spindle Speed Range Selector Auto-Downfeed Direction Pin Manual/Power Downfeed Selector Fine Downfeed Handwheel Downfeed Clutch Lever Coarse Downfeed Lever Adjustable Downfeed Stop Quill Spindle Figure 2. Model SB1024 belt housing and headstock identification.

Quill Lock Lever Dial Indicator Rod 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.

SB1024 belt housing & headstock identification

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-

SB1024/SB1025/SB1026

I N T R O D U C T I O N

For Machines Mfg. Since 8/09

Model SB1025/SB1026 Belt Housing & Headstock Identification

Motor Assembly High/Low Range Lever Belt Tension Adjustment Lever Spindle Brake Auto-Downfeed Rate Selector Auto-Downfeed Direction Pin Motor Lock Lever Spindle Speed Range Selector Manual/Power Downfeed Selector Fine Downfeed Handwheel Downfeed Clutch Lever Adjustable Downfeed Stop Quill Spindle Coarse Downfeed Lever Quill Lock Lever Dial Indicator Rod Figure 3. Model SB1025/SB1026 belt housing and headstock identification (Model SB1025 shown).

SB1025-26 belt housing & headstock identification -6-

For Machines Mfg. Since 8/09

I N T R O D U C T I O N

SB1024/SB1025/SB1026

Model SB1024 Mill 9 x 42 1PH Var.

Product Dimensions

Weight........................................................................................................................................................... 2000 lbs.

Width (side-to-side) x Depth (front-to-back) x Height..................................................................... 63 x 58 x 87 in.

Footprint (Length x Width)....................................................................................................................... 36 x 24 in.

Space Required for Full Range of Movement (Width x Depth)......................................................... 81-1/2 x 66 in.

Shipping Dimensions

Type.......................................................................................................................................................... Wood Crate Content.......................................................................................................................................................... Machine Weight........................................................................................................................................................... 1984 lbs.

Length x Width x Height................................................................................................................... 54 x 54 x 73 in.

Electrical

Power Requirement......................................................................................................... 220V, Single-Phase, 60 Hz Prewired Voltage................................................................................................................................................ 220V Full-Load Current Rating.................................................................................................................................... 14A Minimum Circuit Size.......................................................................................................................................... 20A Connection Type..................................................................................................................................... Cord & Plug Power Cord Included.............................................................................................................................................. No Recommended Power Cord............................................................................. “S”-Type, 3-Wire, 14 AWG, 300 VAC Plug Included.......................................................................................................................................................... No Recommended Plug Type..................................................................................................................................... 6-20 Switch Type....................................................................................... Control Panel w/Magnetic Switch Protection

Motors Main

Horsepower............................................................................................................................................... 2 HP Phase............................................................................................................................................ Single-Phase Amps........................................................................................................................................................... 14A Speed................................................................................................................................................ 1725 RPM Type............................................................................................................. AEVF Capacitor-Start Induction Power Transfer ................................................................................................................................ Belt Drive Bearings.................................................................................................... Sealed & Permanently Lubricated Centrifugal Switch/Contacts Type..................................................................................................... External

Model SB1024 Page 1 of 3

-7-

SB1024/SB1025/SB1026

I N T R O D U C T I O N

For Machines Mfg. Since 8/09

Main Specifications Operation Info

Spindle Travel............................................................................................................................................ 5 in.

Max Distance Spindle to Column........................................................................................................... 19 in.

Max Distance Spindle to Table............................................................................................................... 19 in.

Longitudinal Table Travel (X-Axis).................................................... 24-1/2 in. (29-1/2 in. w/o Power Feed) Cross Table Travel (Y-Axis).................................................................................................................... 13 in.

Vertical Table Travel (Z-Axis)................................................................................................................. 16 in.

Ram Travel............................................................................................................................................... 13 in.

Turret or Column Swivel (Left /Right)............................................................................................... 360 deg.

Head Tilt (Left/Right)........................................................................................................................... 90 deg.

Head Tilt (Front/Back).......................................................................................................................... 45 deg.

Drilling Capacity for Cast Iron................................................................................................................. 1 in.

Drilling Capacity for Steel...................................................................................................................... 3/4 in.

End Milling Capacity................................................................................................................................. 1 in.

Face Milling Capacity................................................................................................................................ 4 in.

Table Info

Table Length............................................................................................................................................ 42 in.

Table Width................................................................................................................................................ 9 in.

Table Thickness......................................................................................................................................... 3 in.

Number of T-Slots........................................................................................................................................... 3 T-Slot Size............................................................................................................................................... 5/8 in.

T-Slots Centers.................................................................................................................................... 2-1/2 in.

Number of Longitudinal Feeds.......................................................................................................... Variable X-Axis Table Power Feed Rate................................................................................................... 0 – 3.34 FPM X/Y-Axis Travel per Handwheel Revolution..................................................................................... 0.200 in.

Z-Axis Travel per Handwheel Revolution......................................................................................... 0.100 in.

Spindle Info

Spindle Taper.............................................................................................................................................. R-8 Number of Vertical Spindle Speeds................................................................................................... Variable Range of Vertical Spindle Speeds........................................................................................... 60 – 4200 RPM Quill Diameter.................................................................................................................................... 3.375 in.

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

Drawbar Thread Size............................................................................................................................ 7/16-20 Drawbar Length................................................................................................................................ 18-1/2 in.

Spindle Bearings.............................................................................................. Angular Contact P4 (ABEC7)

Construction

Spindle Housing/Quill.................................................................. Chrome-Plated & Precision-Ground Steel Table............................................................................................... Hardened & Precision-Ground Cast Iron Head................................................................................................................................ Meehanite Cast Iron Column/Base................................................................................................................... Meehanite Cast Iron Base.................................................................................................................................................... Cast Iron Paint Type/Finish.............................................................................................................................. Urethane

Other

Country of Origin ........................................................................................................................................... Taiwan Warranty ......................................................................................................................................................... 1 Year Approximate Assembly & Setup Time ......................................................................................................... 2 Hours Serial Number Location ........................................................................................ ID Label on Column Right Side Sound Rating .................................................................................................................................................... 55 dB ISO 9001 Factory ................................................................................................................................................... No Certified by a Nationally Recognized Testing Laboratory (NRTL) .................................................................... No

Model SB1024 Page 2 of 3

-8-

For Machines Mfg. Since 8/09

I N T R O D U C T I O N

SB1024/SB1025/SB1026

Model SB1025 Mill 9" x 42" 3PH Product Dimensions

Weight........................................................................................................................................................... 1918 lbs.

Width (side-to-side) x Depth (front-to-back) x Height..................................................................... 63 x 58 x 81 in.

Footprint (Length x Width)....................................................................................................................... 36 x 24 in.

Space Required for Full Range of Movement (Width x Depth)......................................................... 81-1/2 x 66 in.

Shipping Dimensions

Type.......................................................................................................................................................... Wood Crate Content.......................................................................................................................................................... Machine Weight........................................................................................................................................................... 2062 lbs.

Length x Width x Height................................................................................................................... 54 x 54 x 74 in.

Electrical

Power Requirement................................................................................................................. 220V, 3-Phase, 60 Hz Prewired Voltage................................................................................................................................................ 220V Full-Load Current Rating...................................................................................................................................... 6A Minimum Circuit Size.......................................................................................................................................... 15A Connection Type..................................................................................................................................... Cord & Plug Power Cord Included.............................................................................................................................................. No Recommended Power Cord............................................................................. “S”-Type, 4-Wire, 14 AWG, 300 VAC Plug Included.......................................................................................................................................................... No Recommended Plug Type.................................................................................................................... NEMA L15-20 Switch Type....................................................................................... Control Panel w/Magnetic Switch Protection Recommended Phase Converter...................................................................................................................... G5844

Motors Main

Horsepower............................................................................................................................................... 2 HP Phase.................................................................................................................................................... 3-Phase Amps..................................................................................................................................................... 6A/5.6A

Speed..................................................................................................................................... 3450 / 1725 RPM Type........................................................................................................................................ AEVF Induction Power Transfer ................................................................................................................................ Belt Drive Bearings.................................................................................................... Sealed & Permanently Lubricated Centrifugal Switch/Contacts Type............................................................................................................. N/A

Model SB1025 Page 1 of 3

-9-

SB1024/SB1025/SB1026

I N T R O D U C T I O N

For Machines Mfg. Since 8/09

Main Specifications Operation Info

Spindle Travel............................................................................................................................................ 5 in.

Max Distance Spindle to Column........................................................................................................... 19 in.

Max Distance Spindle to Table............................................................................................................... 18 in.

Longitudinal Table Travel (X-Axis).................................................... 24-1/2 in. (29-1/2 in. w/o Power Feed) Cross Table Travel (Y-Axis).................................................................................................................... 13 in.

Vertical Table Travel (Z-Axis)................................................................................................................. 16 in.

Ram Travel............................................................................................................................................... 13 in.

Turret or Column Swivel (Left /Right)............................................................................................... 360 deg.

Head Tilt (Left/Right)........................................................................................................................... 90 deg.

Head Tilt (Front/Back).......................................................................................................................... 45 deg.

Drilling Capacity for Cast Iron................................................................................................................. 1 in.

Drilling Capacity for Steel...................................................................................................................... 3/4 in.

End Milling Capacity................................................................................................................................. 1 in.

Face Milling Capacity................................................................................................................................ 4 in.

Table Info

Table Length............................................................................................................................................ 42 in.

Table Width................................................................................................................................................ 9 in.

Table Thickness......................................................................................................................................... 3 in.

Number of T-Slots........................................................................................................................................... 3 T-Slot Size............................................................................................................................................... 5/8 in.

T-Slots Centers.................................................................................................................................... 2-1/2 in.

Number of Longitudinal Feeds.......................................................................................................... Variable X-Axis Table Power Feed Rate................................................................................................... 0 – 3.34 FPM X/Y-Axis Travel per Handwheel Revolution..................................................................................... 0.200 in.

Z-Axis Travel per Handwheel Revolution......................................................................................... 0.100 in.

Spindle Info

Spindle Taper.............................................................................................................................................. R-8 Number of Vertical Spindle Speeds............................................................................................................. 16 Range of Vertical Spindle Speeds........................................................................................... 80 – 5600 RPM Quill Diameter.................................................................................................................................... 3.375 in.

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

Drawbar Thread Size............................................................................................................................ 7/16-20 Drawbar Length................................................................................................................................ 18-1/2 in.

Spindle Bearings............................................................................................. Angular Contact P4 (ABEC-7)

Construction

Spindle Housing/Quill.................................................................. Chrome-Plated & Precision-Ground Steel Table............................................................................................... Hardened & Precision-Ground Cast Iron Head................................................................................................................................ Meehanite Cast Iron Column/Base................................................................................................................... Meehanite Cast Iron Base.................................................................................................................................................... Cast Iron Paint Type/Finish.............................................................................................................................. Urethane

Other

Country of Origin ........................................................................................................................................... Taiwan Warranty ......................................................................................................................................................... 1 Year Approximate Assembly & Setup Time ......................................................................................................... 2 Hours Serial Number Location ........................................................................................ ID Label on Column Right Side Sound Rating .................................................................................................................................................... 55 dB ISO 9001 Factory ................................................................................................................................................... No Certified by a Nationally Recognized Testing Laboratory (NRTL) .................................................................... No

Model SB1025 Page 2 of 3

-10-

For Machines Mfg. Since 8/09

I N T R O D U C T I O N

SB1024/SB1025/SB1026

Model SB1026 Mill 9" x 42" 1PH Product Dimensions

Weight........................................................................................................................................................... 1940 lbs.

Width (side-to-side) x Depth (front-to-back) x Height..................................................................... 63 x 58 x 86 in.

Footprint (Length x Width)....................................................................................................................... 36 x 24 in.

Space Required for Full Range of Movement (Width x Depth)......................................................... 81-1/2 x 66 in.

Shipping Dimensions

Type.......................................................................................................................................................... Wood Crate Content.......................................................................................................................................................... Machine Weight........................................................................................................................................................... 2140 lbs.

Length x Width x Height................................................................................................................... 54 x 54 x 73 in.

Electrical

Power Requirement......................................................................................................... 220V, Single-Phase, 60 Hz Prewired Voltage................................................................................................................................................ 220V Full-Load Current Rating.................................................................................................................................... 14A Minimum Circuit Size.......................................................................................................................................... 20A Connection Type..................................................................................................................................... Cord & Plug Power Cord Included.............................................................................................................................................. No Recommended Power Cord............................................................................. “S”-Type, 3-Wire, 14 AWG, 300 VAC Plug Included.......................................................................................................................................................... No Recommended Plug Type..................................................................................................................................... 6-20 Switch Type....................................................................................... Control Panel w/Magnetic Switch Protection

Motors Main

Horsepower............................................................................................................................................... 2 HP Phase............................................................................................................................................ Single-Phase Amps........................................................................................................................................................... 14A Speed................................................................................................................................................ 1725 RPM Type............................................................................................................. AEVF Capacitor-Start Induction Power Transfer ................................................................................................................................ Belt Drive Bearings.................................................................................................... Sealed & Permanently Lubricated Centrifugal Switch/Contacts Type..................................................................................................... External

Model SB1026 Page 1 of 3

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I N T R O D U C T I O N

For Machines Mfg. Since 8/09

Main Specifications Operation Info

Spindle Travel............................................................................................................................................ 5 in.

Max Distance Spindle to Column........................................................................................................... 19 in.

Max Distance Spindle to Table............................................................................................................... 18 in.

Longitudinal Table Travel (X-Axis).................................................... 24-1/2 in. (29-1/2 in. w/o Power Feed) Cross Table Travel (Y-Axis).................................................................................................................... 13 in.

Vertical Table Travel (Z-Axis)................................................................................................................. 16 in.

Ram Travel............................................................................................................................................... 13 in.

Turret or Column Swivel (Left /Right)............................................................................................... 360 deg.

Head Tilt (Left/Right)........................................................................................................................... 90 deg.

Head Tilt (Front/Back).......................................................................................................................... 45 deg.

Drilling Capacity for Cast Iron................................................................................................................. 1 in.

Drilling Capacity for Steel...................................................................................................................... 3/4 in.

End Milling Capacity................................................................................................................................. 1 in.

Face Milling Capacity................................................................................................................................ 4 in.

Table Info

Table Length............................................................................................................................................ 42 in.

Table Width................................................................................................................................................ 9 in.

Table Thickness......................................................................................................................................... 3 in.

Number of T-Slots........................................................................................................................................... 3 T-Slot Size............................................................................................................................................... 5/8 in.

T-Slots Centers.................................................................................................................................... 2-1/2 in.

Number of Longitudinal Feeds.......................................................................................................... Variable X-Axis Table Power Feed Rate................................................................................................... 0 – 3.34 FPM X/Y-Axis Travel per Handwheel Revolution..................................................................................... 0.200 in.

Z-Axis Travel per Handwheel Revolution......................................................................................... 0.100 in.

Spindle Info

Spindle Taper.............................................................................................................................................. R-8 Number of Vertical Spindle Speeds............................................................................................................... 8 Range of Vertical Spindle Speeds........................................................................................... 80 – 2800 RPM Quill Diameter.................................................................................................................................... 3.375 in.

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

Drawbar Thread Size............................................................................................................................ 7/16-20 Drawbar Length................................................................................................................................ 18-1/2 in.

Spindle Bearings............................................................................................. Angular Contact P4 (ABEC-7)

Construction

Spindle Housing/Quill.................................................................. Chrome-Plated & Precision-Ground Steel Table............................................................................................... Hardened & Precision-Ground Cast Iron Head................................................................................................................................ Meehanite Cast Iron Column/Base................................................................................................................... Meehanite Cast Iron Base.................................................................................................................................................... Cast Iron Paint Type/Finish.............................................................................................................................. Urethane

Other

Country of Origin ........................................................................................................................................... Taiwan Warranty ......................................................................................................................................................... 1 Year Approximate Assembly & Setup Time ......................................................................................................... 2 Hours Serial Number Location ........................................................................................ ID Label on Column Right Side Sound Rating ................................................................................................................................................... 55 dB ISO 9001 Factory ................................................................................................................................................... No Certified by a Nationally Recognized Testing Laboratory (NRTL) .................................................................... No

Model SB1026 Page 2 of 3

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For Machines Mfg. Since 8/09

S A F E T Y

SB1024/SB1025/SB1026

Understanding Risks of Machinery

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 as follows:

Death or catastrophic harm WILL occur.

Death or catastrophic harm COULD occur.

Moderate injury or fire MAY occur.

Machine or property damage may occur.

Basic Machine Safety

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.

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, long term 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.

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.

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.

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SB1024/SB1025/SB1026

S A F E T Y

For Machines Mfg. Since 8/09

Entanglement:

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.

Loose clothing, gloves, neckties,

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.

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.

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.

Work Area:

Clutter and dark shadows increase the risks of accidental injury. Only operate this item in a clean, non-glaring, and well lighted work area.

Properly Functioning Equipment:

this documentation.

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

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.

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.

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.

Health Hazards:

Certain cutting fluids and lubricants, or dust/smoke created when cutting, may contain chemicals known to the State of California 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.

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.

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.

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For Machines Mfg. Since 8/09

S A F E T Y

SB1024/SB1025/SB1026

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.

The mill is a

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.

2. Safety Accessories:

from the cutting operation can cause eye injury or blindness.

Flying chips or debris Always use a chip guard in addition to your safety glasses or use a face shield when milling.

3. Work Holding:

Milling a workpiece that is 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.

To avoid tool or workpiece

7. Chip Cleanup:

Chips from the operation are sharp and hot, which 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:

Operating 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.

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.

Changing spindle

9. Cutting Tool Usage:

Cutting tools have very 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.

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SB1024/SB1025/SB1026

P R E P A R A T I O N

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.

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

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.

For Lifting (Page 20)

• A forklift or other power lifting device rated for more than the weight of the machine.

• Two lifting web straps rated for the weight of the machine.

• At least two other persons to help with the operation.

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.

For Power Connection

• We recommend a qualified electrician to ensure a safe and code-compliant connection to the power source. (Refer to

Page 24 for details.)

6.

Connect the machine to the power source.

7.

Test run the machine to make sure it functions properly and is ready for operation.

For Assembly

• Cotton disposable rags • Cleaner/degreaser (see Page 18) • Safety -16-

For Machines Mfg. Since 8/09

P R E P A R A T I O N

Unpacking

This item was carefully packaged to prevent damage during transport. If you discover any damage, please immediately call Customer Service at (360) 734-1540 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.

D E

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 4) Qty A.

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

B.

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

C.

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

D.

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

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.

Knee Crank ....................................................1

N.

SB1025/SB1026 Belt Housing Safety Covers .................................................2

O.

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

P.

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

N O F P A C H M G

SB1024/SB1025/SB1026

L K J B Figure 4. Small part inventory.

I

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P R E P A R A T I O N

Cleaning & Protecting

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, the following process works well in most situations.

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 surface to make sure they will not damage it.

For Machines Mfg. Since 8/09

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.

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.

Cleaning

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

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For Machines Mfg. Since 8/09

P R E P A R A T I O N

Location

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 to perform operations safely. Shadows, glare, or strobe effects that may distract or impede the operator must be eliminated.

SB1024/SB1025/SB1026

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.

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

Wall 30" 23" 30" 24" 38" 81 ⁄ 1 2 " 36" 66"

Figure 5. Space required for full range of movement.

= Power connection -19-

SB1024/SB1025/SB1026

Lifting & Moving

P R E P A R A T I O N 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.

For Machines Mfg. Since 8/09

2.

Place the lifting web straps under the ram and connect them to the safety hook, as illustrated in Figure 6.

Note:

Place padding between the straps and the

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

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 6 (refer to Ram Movement on Page 36 and

Headstock Movement on Page 32 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.

Lifting Web Straps

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Figure 6. Using web straps to lift the mill.

For Machines Mfg. Since 8/09

P R E P A R A T I O N

Leveling & Mounting

Generally, you can either bolt your machine to the floor or mount it on machine mounts.

Although not required, we recommend that you secure the machine to the floor and level it while doing so. Because this is an optional step and floor materials may vary, hardware for securing the machine to the floor is not included.

SB1024/SB1025/SB1026

Bolting to Concrete Floors

Anchor Bolt 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.

Lag Screw and Anchor

Leveling

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.

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.

Figure 8. Common types of fasteners for bolting machinery to concrete floors.

Figure 7. Example of a precision level.

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SB1024/SB1025/SB1026

Assembly

Ball Handles

The ball handles for either end of the X-axis leadscrew have spring-loaded, keyed center bushings, as shown in Figure 9. This allows them to disengage from the leadscrew when using the power feed, avoiding an entanglement hazard.

X-Axis Spring-Loaded Bushing P R E P A R A T I O N Ball Handle Handle

For Machines Mfg. Since 8/09

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.

5.

Remove the hex nut from the Y-axis leadscrew.

6.

Align the keyway of the remaining ball handle with the leadscrew key, slide the Y-axis ball handle (see Figure 9) 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.

Knee Crank

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

Figure 10.

Y-Axis Ball Handle Figure 9. Ball handle assemblies.

To install the ball handles:

1.

Remove the hex nuts from both ends of the X-axis leadscrew.

2.

Identify the two ball handles with the spring-loaded center bushings (see

Figure 9).

3.

Position the ball handle so that the protruding part of the bushing is facing toward the table, align the keyway with the X-axis leadscrew key, then slide it onto the leadscrew.

Knee Crank Teeth Engaged Figure 10. Knee crank and shaft teeth engaged.

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For Machines Mfg. Since 8/09

P R E P A R A T I O N

Way Covers

1.

Remove the five button-head cap screws shown in Figure 11 from the front of the saddle and knee, position the pleated way cover in place, then secure it with the removed cap screws.

SB1024/SB1025/SB1026

2.

Remove the four button-head cap screws shown in Figure 12 from the column and the rear of the table, position the rear way cover in place, then secure it with the removed cap screws.

Cap Screws Cap Screws Figure 12. Rear way cover installed.

Figure 11. Front way cover installed.

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P R E P A R A T I O N

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.

Note About Extension Cords: Using an

incorrectly sized extension cord may decrease the life of electrical components on the machine.

Note About 3-Phase Power: DO NOT use a

static phase converter to create 3-phase power— it can quickly decrease the life of electrical components on the machine. If you must use a phase converter, only use a rotary phase converter and connect the manufactured leg to the L2 power connection terminal, shown in the wiring diagram on Page 68.

SB1024 (220V)

Full Load Amp Draw ............................... 14 Amps Required Voltage Range ................................ 220V Phase ................................................. Single-Phase Frequency ...................................................... 60 Hz Minimum Circuit Size ............................. 20 Amps Recommended Power Cord ...14 AWG/3C/300VAC Recommended Plug/Receptacle .......... NEMA 6-20 Minimum Extension Cord Size ................ 14 AWG Maximum Extension Cord Length ................ 50 ft.

SB1025 (220V 3-Phase)

Full Load Amp Draw ........................... 6/5.6 Amps Required Voltage Range ................................ 220V Phase ..........................................................3-Phase Frequency ...................................................... 60 Hz Minimum Circuit Size ............................. 15 Amps Recommended Power Cord ...14 AWG/4C/300VAC Recommended Plug/Receptacle ......NEMA L15-20 Minimum Extension Cord Size ................ 14 AWG Maximum Extension Cord Length ................ 50 ft.

SB1026 (220V)

Full Load Amp Draw ............................... 14 Amps Required Voltage Range ................................ 220V Phase ................................................. Single-Phase Frequency ...................................................... 60 Hz Minimum Circuit Size ............................. 20 Amps Recommended Power Cord ...14 AWG/3C/300VAC Recommended Plug/Receptacle .......... NEMA 6-20 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 listed above.

2.

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

3.

Terminate the power cord as illustrated in the Electrical Box Wiring Diagrams on

Pages 65–68.

4. We recommend that you connect the other

end to a NEMA 6-20 plug (SB 1024/26) or NEMA L15-20 plug (SB1025).

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For Machines Mfg. Since 8/09

P R E P A R A T I O N

SB1024/SB1025/SB1026

Initial Lubrication

The machine was fully lubricated at the factory, but we strongly recommend that before performing the Test Run you inspect all lubrication points yourself and provide additional lubrication if necessary. Refer to the

Lubrication section on Page 51 for specific

details.

5.

Move the downfeed selector to the manual (forward) position so that the spindle does not downfeed during this test (refer to the

Downfeed Operations section on Page 43

for detailed instructions).

6.

Push the emergency STOP button in (see

Figures 13–14), then twist it clockwise until

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

Test Run

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.

Spindle Direction Switch ON Button Power Lamp

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 61 for solutions to common problems that may occur with all mills. If you need additional help, contact our Tech Support at (360) 734-1540.

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

2.

Clear assembly and preparation.

3.

Make sure that the mill is properly lubricated (refer to the Lubrication section on Page 51 for specific details).

4.

Set the spindle speed to the low range (refer to the Setting Spindle Speed Range section beginning on Page 37 for detailed instructions).

OFF Button Emergency STOP Figure 13. Model SB1025 control panel.

Spindle Direction Switch ON Button OFF Button Power Lamp Emergency STOP Figure 14. Model SB1024/SB1026 control panel.

7.

Press the ON button to allow power to flow to the motor, then turn the spindle direction switch to the forward (right) position to start spindle rotation.

Note:

For the Model SB1024, turn the spindle

direction switch to the F1 position.

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P R E P A R A T I O N

For Machines Mfg. Since 8/09

8.

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

2.

Refer to the Table Movement section, beginning on Page 29, to understand how the power feed, table locks, and limit switch function.

10.

11.

— 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.

9.

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

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.

— 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.

Press the OFF button, then turn the spindle direction switch to the off (middle) position to prevent the spindle from starting when you next use the ON button.

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 (360) 734 1540 for assistance.

3.

Loosen the table locks on the front of the table.

4.

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

Note: 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.

8.

9.

There are 110V outlets on the right side of

the electrical cabinet that can be used for the power feed or other 110V accessories.

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

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

Confirm that the table stops moving when

10.

the limit stop presses against the limit switch plunger.

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 with the next page to perform the Spindle Break-In and

Adjustments & Inspections procedures.

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.

-26-

For Machines Mfg. Since 8/09

P R E P A R A T I O N

SB1024/SB1025/SB1026

Spindle Break-In

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

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 33 for detailed instructions.

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 25.

2.

Make sure the spindle is at a complete stop.

3.

Set the spindle speed to the low range (refer to Setting Spindle Speed Range beginning on Page 37 for detailed instructions).

Inspections & Adjustments

The following list of adjustments were performed at the factory before the machine was shipped: • Gib Adjustment .................................Page 58 • Leadscrew Backlash Adjustment .........................................Page 59 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!

-27-

SB1024/SB1025/SB1026

O P E R A T I O N

Operation Overview

The purpose of this overview is to give an example of a typical milling operation. Read through the steps below to better understand the controls and functions described later in this manual, so that you will know how they are used to successfully operate the mill.

This overview is not intended to be a step-by-step operational guide.

To reduce the risk of serious injury when using this machine, read and understand this entire manual before beginning any operations.

In a typical milling operation, the operator does the following:

1.

Examines the workpiece to make sure it is

suitable for milling.

2.

Firmly clamps the workpiece to the table.

3.

Installs the correct cutting tool for the operation.

4.

Uses the manual downfeed and table controls to confirm the correct positioning of the cutting tool and workpiece for the operation. If the X-axis power feed will be used during the operation, the operator confirms the speed and length of table movement required.

For Machines Mfg. Since 8/09

Loose hair, clothing, or jewelry could get caught in machinery and cause serious personal injury. Keep these items away from moving parts at all times to reduce this risk.

During operation, small metal chips may become airborne, leading to serious eye injury. Wear safety glasses to reduce this risk.

5.

Configures the mill for the correct spindle speed of the operation.

6.

Puts on personal protective gear and makes sure the workpiece and table are clear of all tools, cords, and other items.

7.

Starts the spindle rotation and performs the operation.

8.

Turns the mill OFF.

-28-

For Machines Mfg. Since 8/09

Control Panel

Use Figures 15–16 and the following descriptions to understand the functions of the mill control panel.

Spindle Direction Switch ON Button O P E R A T I O N Power Lamp

SB1024/SB1025/SB1026

ON Button:

Allows power flow to the motor. The

spindle direction switch must be used to start the spindle rotation.

Power Lamp:

Illuminates when the mill is

connected to a power source.

Emergency STOP Button:

power flow to the motor.

Stops the flow of power to the motor. Twist clockwise until it pops out to reset it, then press the ON button to re-establish

OFF Button:

Stops power flow to the motor.

Emergency STOP Spindle Direction Switch OFF Button Figure 15. Model SB1025 control panel.

ON Button Power Lamp

Table Movement

The mill table moves in three directions, as illustrated in Figure 17:

X-axis (longitudinal)

• Y-axis (cross) • Z-axis (vertical) These movements are controlled by table ball handles and the Z-axis crank. Additionally, the table can be moved along the X-axis with the power feed.

X-Axis or Longitudinal Travel (Left & Right)

Emergency STOP OFF Button

Y-Axis or Cross Travel (In & Out)

Figure 16. Model SB1024/SB1026 control panel.

Spindle Direction Switch:

Starts, stops, and

reverses the direction of spindle rotation.

Note: The Model SB1025 has two positions for

each direction that electronically change the speed of the motor and work in conjunction with the belt housing controls to set the spindle speed range (refer to "To set the spindle speed range for the Model SB1025" on Page 39 for additional details).

Z-Axis or Vertical Elevation (Up & Down)

Figure 17. The directions of table movement.

-29-

SB1024/SB1025/SB1026

O P E R A T I O N

Graduated Index Rings

The table ball handles and elevation crank have graduated index rings attached (see Figure

18) that are used to accurately determine table

movement in increments, as listed in the table below: For Machines Mfg. Since 8/09

Always keep the table locked in place unless table movement is required for your operation. Unexpected table and workpiece movement could cause the cutter to bind with the workpiece, which could result in personal injury or damage to the cutter and workpiece.

Axis

X Y Z

Individual Increment

0.001" 0.001" 0.001"

One Full Revolution

0.200" 0.200" 0.100"

Table Locks

Refer to Figure 19 for the locations of the locks used to secure the table in place.

X-Axis Locks Index Rings Figure 18. Graduated table index rings.

Z-Axis Locks Y-Axis Lock Figure 19. Locations of table locks.

-30-

For Machines Mfg. Since 8/09

O P E R A T I O N

SB1024/SB1025/SB1026

X-Axis Power Feed

The mill is equipped with a power feed unit for X-axis table movement. Refer to the illustration in Figure 20 and the descriptions below to understand the functions of the various components of the power feed system.

H. X-Axis Ball Handle:

Manually moves the

table.

I. Graduated Index Ring:

Display the distance

of table travel in 0.001" increments, with one full revolution equal to 0.200" of table travel.

I To confirm the power feed settings that you will be using during operation, we recommend that you use the power feed to move the table through the intended cutting path before starting the spindle rotation and taking the cut A B C D E F G

Figure 20. Power feed system components.

H

A. Limit Switch:

Stops table movement when

either of the switch side plungers are pressed by the limit stops.

Tool Needed

Hex Wrench 12mm .............................................. 1

To operate the X-axis power feed:

1.

Loosen the X-axis table locks (refer to

Figure 19 on Page 30 for locations).

Qty 2.

Position the limit stops along the front table

slot to limit the distance of table travel that is correct for your operation.

Note:

Make sure the cap screws firmly lock the

limit stops in place when positioned.

B. Limit Stop:

Restricts table movement when

positioned along the front of the table.

C. Rapid Traverse Button:

Moves the table at

full speed when it is in motion.

3.

Turn the speed dial all the way counterclockwise to slowest setting, move the directional lever to neutral (middle) position, then flip the power switch up to turn the unit ON.

D. Directional Lever:

neutral.

Selects the direction of

table movement. The middle position is

4.

With your hand poised over the power switch in case you need to suddenly turn the unit OFF, move the directional lever in the desired direction of table travel.

E. Speed Dial:

Controls the speed of the power

feed. Turning the dial clockwise causes the table to move faster.

5.

Use the speed dial to slowly bring the speed of movement up to the desired rate.

F. Circuit Breaker Reset Button:

overloaded and shuts down.

Resets

the internal circuit breaker if the unit is

G. Power Switch:

Turns the power feed ON and

OFF.

6.

When you are finished using the power feed, turn the unit OFF, then rotate the speed dial all the way clockwise and move the directional lever to the neutral (middle) position to avoid unexpected table movement when you next flip the power switch up.

-31-

SB1024/SB1025/SB1026

O P E R A T I O N

Head Movement

The head tilts 45° back and forth, and rotates 90° left and right, as shown in Figures 21–22.

For Machines Mfg. Since 8/09

Always lock the head firmly in place after tilting or rotating it. Unexpected movement of the head during operations could cause damage to the cutter or workpiece.

45° Tool Needed Qty

Wrench 19mm .......................................................1

Tilting Head

1.

DISCONNECT MILL FROM POWER!

2.

Loosen the three tilt lock bolts on the right side of the ram adapter shown in Figure 23.

Tilt Bolt !

Figure 21. Head tilts 45° back-and-forth.

90° Figure 22. Head tilts 90° left-and-right.

Lock Bolts Figure 23. Head tilting controls.

3.

Use one hand to apply pressure to the head in the direction of rotation, then slowly rotate the tilt bolt. Rotating this bolt clockwise will tilt the head back.

4.

When the head is in the correct position for your operation, re-tighten all three lock bolts.

-32-

For Machines Mfg. Since 8/09

Rotating Head

1.

DISCONNECT MILL FROM POWER!

2.

Loosen the four rotation lock bolts on the face of the head shown in Figure 24.

!

Rotation Bolt O P E R A T I O N

SB1024/SB1025/SB1026

Tramming Spindle

After positioning the head at an angle and when your operation requires that the spindle axis be precisely perpendicular to the table, you must tram or align the spindle with the table to ensure the spindle is exactly 90° to the table.

This procedure involves mounting a dial test indicator to the quill or spindle, rotating it around the table, and adjusting the spindle axis (Z-axis) 90° to the table X- and Y-axes, as illustrated in Figure 25.

Lock Bolts

Spindle Z-Axis

Figure 24. Head rotating controls.

3.

Use one hand to apply pressure to the head in the direction of tilt, then slowly turn the rotation bolt.

4.

Re-tighten the lock bolts when you have the head in the desired position.

Y-Axis 90º 90º X-Axis Table

Figure 25. Spindle axis perpendicular to the table X- and Y-axes.

We encourage you to research the many variations of spindle tramming to find the one that works best for you. If you do not already have a preference for performing this operation, use the following widely-used procedure for accurately tramming the spindle to the table.

Keep in mind that all workpiece top surfaces are not exactly parallel with the table top. You may choose to tram the spindle to the top surface of the workpiece after it is mounted instead of that of the table.

-33-

SB1024/SB1025/SB1026

O P E R A T I O N

For Machines Mfg. Since 8/09

Tools Needed

Dial Test Indicator

Qty

(with at least 0.0005" resolution) ..................1

Indicator Holder (mounted on the quill/spindle) ......................1

Precision Parallel Block (at least 9" in length) .....................................1

Note:

A precision-ground plate can be substituted for the parallel blocks. Keep in mind that the farther the indicator point can be placed from the spindle axis, the more accurate the alignment measurements will be.

4.

Install the indicator holder into the spindle or onto the quill, then mount the indicator onto it so that the point is as parallel to the block as possible (see the illustration in

Figure 26 for an example).

Indicator Holder Dial Test Indicator Spindle

To tram the spindle to the table:

1.

DISCONNECT MILL FROM POWER!

2.

Prepare the mill by performing the following tasks: • Stone the table to remove all nicks and burrs, then clean off all debris. Verify the table is clean by running your hand over the top of it.

• Position the table for the milling operation you intend to perform after the tramming—preferably centered to the saddle.

• Tighten any table, knee, quill, or ram locks that should be tight during the intended milling operation.

3.

Place the parallel block underneath the spindle.

Parallel Block Table

Figure 26. Dial test indicator mounted.

5.

To measure spindle alignment along the X-axis, place the parallel block directly under the spindle and indicator across the length of the table, as illustrated in Figure 27.

Note:

If you must re-position the quill or the

knee to accommodate the above step, then review the tasks in Step 2 to make sure the mill is properly prepared for the tramming operation.

Table (Top View) Parallel Block Indicator Spindle

Figure 27. Parallel block positioned for the X-axis measurement (top view).

-34-

For Machines Mfg. Since 8/09

O P E R A T I O N

SB1024/SB1025/SB1026

Note:

Generally, the goal in the next steps is to

get the difference of the indicator readings between the end of the parallel bar down to 0.0005". However, the acceptable variance will depend on the requirements for your operation.

6.

Rotate the spindle by hand so that the indicator point rests on one end of the parallel block, as illustrated in Figure 27, then zero the dial.

7.

Rotate the spindle so that the indicator point rests in the same manner on other end of the block, then read the dial.

— If the indicator dial still reads zero or is within the acceptable variance, continue on with Step 8.

— If the indicator dial has moved from zero beyond the acceptable variance, you will need to compensate for that amount by rotating the head left or right. Repeat

Steps 5–6 until you are satisfied with the

spindle axis alignment along the table X-axis.

Note:

Keep one of the rotation lock bolts

just snug so that the head does not move loosely while you adjust it small amounts. Remember to tighten the rotation lock bolts after adjusting the head.

8.

Place the parallel block directly under the spindle and across the width of the table, as illustrated in Figure 28.

9.

Figure 28. Parallel block positioned for the Y-axis measurement (top view).

Rotate the spindle so that the indicator point

10.

Table (Top View) Indicator Spindle

Figure 28, then zero the dial.

Parallel Block rests on the parallel bar, as illustrated in Rotate the spindle so that the indicator point rests on the other end of the bar in the same manner, then read the dial.

— If the indicator dial still reads zero or is within the acceptable variance, the spindle is precisely perpendicular to the table in both the X- and Y-axes and the tramming procedure is complete.

— If the indicator dial has moved from zero beyond the acceptable variance, you will need to compensate for that amount by tilting the head forward or back. Repeat

Steps 9–10 until you are satisfied with

the spindle axis alignment along the table Y-axis.

Note:

Keep one of the tilt lock bolts just

snug so that the head does not move loosely while you adjust it small amounts. Remember to tighten the tilt lock bolts after adjusting the head.

-35-

SB1024/SB1025/SB1026

O P E R A T I O N

For Machines Mfg. Since 8/09

Ram Movement

The ram travels back and forth 13" and rotates 360° in either direction around the turret.

Tool Needed Qty

Wrench 19mm .......................................................1

Moving Ram Back-and-Forth

1.

DISCONNECT MILL FROM POWER!

2.

Loosen the two lock levers shown in

Figure 29 on the right side of the ram.

!

Lock Levers Always lock the head firmly in place after tilting or rotating it. Unexpected movement of the head during operations could cause damage to the cutter or workpiece.

Rotating Ram

1.

DISCONNECT MILL FROM POWER!

2.

Loosen the four lock bolts on top of the turret (see Figure 30).

Note:

There are two lock bolts on either side of

the ram.

!

Lock Bolts (2 of 4) Rotation Scale Adjustment Bolt Figure 29. Ram back-and-forth movement controls.

3.

Make sure there are no obstructions to ram travel, especially with the spindle tool around the workpiece, then slowly rotate the adjustment bolt to move the ram. Rotating the bolt clockwise will move the ram back.

4.

Re-tighten the lock levers after you have re positioned the ram.

Figure 30. Ram rotating controls.

Note:

In the next step, take care not to entangle

or stretch the electrical cabling as you move the ram around the turret.

3.

Push on the head to manually rotate it. Use the rotation scale to determine the correct position for your operation, then re-tighten the four lock bolts to secure the ram in place.

-36-

For Machines Mfg. Since 8/09

O P E R A T I O N

SB1024/SB1025/SB1026

Setting Spindle Speed

Using the correct spindle speed is important for safe and satisfactory results, as well as maximizing tool life.

Setting Spindle Speed Range

Setting the spindle speed range involves engaging and disengaging a spindle spline that uses gearing to increase or decrease the range of spindle speeds.

To set the spindle speed for your operation, you will need to: (1) Determine the best spindle speed for the cutting task, and (2) configure the mill controls to produce the required spindle speed.

Determining Spindle Speed

Many variables affect the optimum spindle speed to use for any given operation, but the two most important are the recommended cutting speed for the workpiece material and the diameter of the cutting tool, as noted in Figure 31: The procedures to set the speed range for the Model SB1024 and Model SB1025/SB1026 differ slightly. Use the appropriate section on the following pages for the mill when selecting the speed range.

To avoid damage to the spindle, gears, or cutting tools: * * Recommended Cutting Speed (FPM) x 12 Tool Dia. (in inches) x 3.14

Double if using carbide cutting tool

= Spindle Speed (RPM) • Spindle rotation must be turned OFF and the spindle must be at a complete stop BEFORE you change the spindle speed range.

Figure 31. Spindle speed formula for milling.

Cutting speed, typically defined in feet per minute (FPM), is the speed at which the edge of a tool moves across the material surface.

• The mill is designed to ONLY operate with the spindle speed range selector in either the high or low position. To avoid damaging the moving parts inside the headstock, never start spindle rotation without the range selector detent pin firmly seated in either the high or low position.

A recommended cutting speed is an ideal speed for cutting a type of material in order to produce the desired finish and optimize tool life.

The books Machinery’s Handbook or Machine

Shop Practice, and some internet sites, provide

excellent recommendations for which cutting speeds to use when calculating the spindle speed. These sources also provide a wealth of additional information about the variables that affect cutting speed and they are a good educational resource.

• When changing the spindle speed range and the direction of spindle rotation reverses, you will need to either change the cutting tool to match the direction of spindle rotation or use the spindle direction switch to compensate for the reversal.

Note:

Regardless of the model of the mill, you

MUST properly perform the Meshing Spindle

& Spindle Clutch procedure as instructed on Page 40 when using the high spindle speed

range.

Also, there are a large number of easy-to-use spindle speed calculators that can be found on the internet. These sources will help you take into account all applicable variables to determine the best spindle speed for the operation.

-37-

SB1024/SB1025/SB1026

O P E R A T I O N

For Machines Mfg. Since 8/09

When the spindle speed range is changed, the direction of spindle rotation will reverse. ALWAYS know which way the spindle is rotating before beginning the cutting operation.

Setting SB1024 Spindle Speed Range

1.

Make sure that the spindle rotation is turned OFF and the spindle is at a complete stop.

2.

Use the chart below to find the spindle speed range that includes the required spindle speed for your operation.

Model SB1024 Spindle Speed Ranges

Low Range 60–500 RPM High Range 500–4200 RPM

3.

Press the spindle speed range lever shown in Figure 32 toward the head to release the detent pin from the detent plate, move selector so that the pin is over the other detent, then release the selector.

— When the selector is pointing to the rear and the front detent is engaged, the low speed range is selected. Conversely, when the lever is pointing toward the front and the rear detent is engaged, the high speed range is selected.

Note:

If it is difficult to move the range selector,

rotate the spindle by hand to help mesh the gears until the selector moves freely.

High Detent Plate Low Model SB1024 Spindle Speed Range Selector Figure 32. Model SB1024 spindle speed range selector.

4.

Make sure the selector detent pin is well seated by attempting to move the selector without pressing it toward the head.

— If the detent pin is well seated, the selector will not move when you attempt to move it as instructed above.

— If the selector does move when you attempt to move it as instructed above, then re-position the selector so that the pin is firmly seated in the detent plate.

5.

Perform the Meshing Spindle & Spindle

Clutch

procedure as instructed on Page 40 to make sure the front spindle pulley and pinion are properly seated into the bull gear.

-38-

For Machines Mfg. Since 8/09

O P E R A T I O N Properly setting the spindle speed range for the Model SB1025/SB1026 involves correctly positioning the high/low range lever AND the spindle speed range selector. ALWAYS make sure these two devices are properly set before beginning the spindle rotation to avoid damaging the machine and voiding the warranty.

SB1024/SB1025/SB1026

3. Low Spindle Speed Range:

then release the knob.

Pull the knob of

the spindle speed range selector (see Figure

33) out to disengage the detent pin, rotate

the selector clockwise to the front position,

Note:

If it is difficult to move the range selector,

rotate the spindle by hand to help mesh the gears until the selector moves freely.

Setting SB1025/SB1026 Spindle Speed Range

1.

Make sure that the spindle rotation is turned OFF and the spindle is at a complete stop.

High/Low Range Lever High Low 2.

Use the charts below to find the spindle speed range that includes the required spindle speed for your operation.

Low High Note:

The Model SB1025 spindle direction switch

on the control panel has four settings that change the direction and speed of the spindle motor for each spindle speed range. Positions

F1 (forward) and R1 (reverse) use the low

motor speed, and F2 and R2 use the high motor speed. Use Figure 15 on Page 29 as a visual reference for the spindle direction switch positions.

Range Selector Figure 33. Model SB1025/SB1026 spindle speed range controls.

4.

Make sure the selector detent pin is well seated by attempting to move the selector without pressing it toward the head.

— If the detent pin is well seated, the selector will not move when you attempt to move it, as instructed above.

Model SB1025 Spindle Speed Ranges

Low Range w/Switch @ F1/R1 80–325 RPM Low Range w/Switch @ F2/R2 High Range w/Switch @ F1/R1 High Range w/Switch @ F2/R2 160–650 RPM 710–2800 RPM 1420–5600 RPM

Model SB1026 Spindle Speed Ranges

Low Range 80–325 RPM High Range 710–2800 RPM — If the selector does move when you attempt to move it, as instructed above, then re-position the selector so that the pin is firmly seated.

-39-

SB1024/SB1025/SB1026

O P E R A T I O N

For Machines Mfg. Since 8/09

5.

Move the high/low range lever back to the right side of the head (see Figure 33.

Note:

Make sure that the range lever is as far

back as it will go before starting the spindle rotation.

Tip:

When the spindle speed range selector and

high/low range lever are correctly set, they will be in the opposite direction from each other.

6. High Spindle Speed Range:

to the front of the head.

Move the high/

low range lever forward so that it is pointing

Note:

Make sure that the range lever is as far

forward as it will go before starting the spindle rotation.

7.

Pull the knob of the spindle speed range selector out to disengage the detent pin, rotate the selector clockwise to the rear position, then release the knob.

Note:

Make sure the selector detent pin is well

seated before starting the spindle rotation.

8.

Perform the Meshing Spindle & Spindle

Clutch procedure as instructed on Page

to make sure the front spindle pulley and pinion are properly seated into the bull gear.

When setting the mill to use the high spindle speed range, the front spindle pulley must mesh with the spindle clutch. Otherwise, you will hear an unusual grinding when spindle rotation is started and damage to these components could be the result.

Meshing Spindle & Spindle Clutch

1.

DISCONNECT MILL FROM POWER!

2.

Set the spindle speed range control(s) for the mill as instructed on the previous pages.

— If you hear/feel the front pulley drop into the spindle clutch when you set the control(s), this procedure is complete and you can continued with spindle speed setup.

— If you do not hear/feel the front pulley drop into the spindle clutch when you set the control(s), continue with Step 3.

Note:

The following step takes experience and

patience to complete properly.

3.

Firmly grasp the spindle, then quickly rotate it in a back-and-forth motion until you hear/ feel the front pulley drop into the spindle clutch.

— If spindle speed range control(s) to re-set the mill to the low range, then repeat

Step 3 until you are certain that the

front pulley is seated into the spindle clutch.

-40-

For Machines Mfg. Since 8/09

O P E R A T I O N

SB1024/SB1025/SB1026

Setting Spindle Speed

The Model SB1024 uses a variable pulley system to set infinite speeds within the speed range selected. The Model SB1025/SB1026 requires re-positioning the V-belt on the pulleys to change spindle speed.

Use the appropriate section below for the mill to select the correct spindle speed.

Setting SB1024 Spindle Speed

1.

Start the spindle rotation.

2.

Slowly rotate the speed handwheel shown in Figure 34 until the desired speed is displayed in the speed indicator window for the speed range selected.

High Range Speed Indicator Variable Speed Handwheel For the Model SB1024 ONLY, always make sure that the spindle rotation has been started and is at a constant speed before using the variable speed handwheel to adjust the spindle speed. Otherwise, the moving parts inside the belt housing could be damaged and void the warranty. Low Range Speed Indicator Figure 34. Model SB1024 variable spindle speed handwheel and indicator windows.

-41-

SB1024/SB1025/SB1026

O P E R A T I O N

Setting SB1025/SB1026 Spindle Speed

1.

DISCONNECT MILL FROM POWER!

2.

Remove the belt housing side covers on both sides of the head to expose the V-belt and pulleys, as shown in Figure 35.

Adjustment Lever SB1025 Low Spindle Speed Range

For Machines Mfg. Since 8/09 220 80 140 325

Switch @ F1/R1

Motor

V-Belt & Pulley Access Lock Lever (1 of 2)

440 160 280 650

Switch @ F2/R2

Motor

Figure 35. V-belt and pulleys exposed (Model SB1026 shown).

3.

Loosen the two motor lock levers, one on either side of the head, then pull the belt tension adjustment lever forward to release the V-belt tension.

4.

Refer to the illustrations in Figures 36–37

and position the V-belt on the pulleys for the desired spindle speed.

Note:

The Models SB1025 and SB1026 produce

slightly different spindle speeds for each V-belt position. Make sure you refer to the correct illustration for the mill.

Also, Model SB1025 has two spindle speeds for each V-belt position that are selected by using the spindle direction switch on the control panel. F1/R1 will produce the lower of the two speeds for each spindle speed range and V-belt position.

SB1025 High Spindle Speed Range

1860 2800 710 1170 1420 2340 3720 5600

Switch @ F1/R1

Motor

Switch @ F2/R2

Motor

Figure 36. Model SB1025 V-belt positions and speeds.

-42-

For Machines Mfg. Since 8/09

SB1026 Low Spindle Speed Range SB1026 High Spindle Speed Range

220 80 140 325 1860 2800 710 1170 Motor Motor

O P E R A T I O N

SB1024/SB1025/SB1026

Downfeed Controls

Spindle downfeed movement on the mill is controlled by three mechanisms: 1) The coarse downfeed handle, 2) the fine downfeed handwheel, and 3) the auto-downfeed system.

Using the Coarse Downfeed Handle

1.

Make sure that the spindle rotation is turned OFF and the spindle is at a complete stop.

2.

To set the downfeed for manual control, pull the downfeed selector knob out, then rotate it clockwise until the selector pin under the knob seats in the forward manual (disengaged) position, as shown in Figure

38 and illustrated in Figure 39 on the next

page.

Note:

It may be necessary to turn the spindle by

hand as you move the selector to enable the gears to mesh.

Figure 37. Model SB1026 V-belt positions and speeds.

Downfeed Selector 5.

To re-tension the V-belt, push the adjustment lever back with moderate force, then re-tighten the two lock levers to secure the motor in place.

6.

Replace the two belt housing side covers before re-connecting the mill to power.

To avoid entanglement hazards, always make sure that the two belt housing safety covers are firmly in place before connecting the mill to power.

Figure 38. Downfeed selector in the manual (disengaged) position.

3.

Make sure the selector pin is firmly seated in the detent by attempting to move the selector without pulling the knob out.

-43-

SB1024/SB1025/SB1026

Manual (Disengaged) Position O P E R A T I O N

For Machines Mfg. Since 8/09

4.

Make sure the pin of the coarse downfeed

handle hub is engaged with one of the detents on the downfeed sleeve (see

Figure 40).

Handle Hub Pin Auto-Downfeed (Engaged) Position Figure 39. Downfeed selector positions.

Figure 40. Coarse downfeed handle hub and detent pin.

5.

Make sure the quill lock lever is loose so that the quill can easily move.

6.

Rotate the coarse downfeed handle around the hub to control the depth of the spindle.

-44-

For Machines Mfg. Since 8/09

O P E R A T I O N

SB1024/SB1025/SB1026

Fine Downfeed Controls

There are a number of devices on the head that are used with the fine downfeed handwheel or the auto-downfeed system. Refer to Figure 41 and the descriptions below to become familiar with these controls.

A B C D E H G F I Figure 41. Fine downfeed controls.

A. Auto-Downfeed Rate Selector:

Selects one of

the three auto-downfeed rates.

B. Fine Downfeed Handwheel:

Manually

controls fine spindle downfeed.

When the spindle rotation is reversed, either by changing the spindle speed range or by using the spindle direction switch, the direction of spindle auto-downfeed will reverse.

C. Auto-Downfeed Direction Pin:

Starts, stops,

and reverses the auto-downfeed direction.

D. Fine Downfeed Clutch Lever:

Engages the

fine/auto-downfeed gears.

E. Downfeed Scale:

inches.

Used with the quill dog,

shows the depth of spindle downfeed in

F. Quill Lock Lever:

Secures the quill in place

for increased stability during operations.

G. Downfeed Stop & Locking Wheel:

wheel is use to secure it in place.

Sets the depth of spindle downfeed. The stop is threaded into position, then the locking

H. Quill Dog:

Moves with the quill and spindle

and disengages the downfeed clutch lever when it engages either the top or the downfeed stop.

I. Downfeed Selector:

Sets the mill for manual

downfeed or auto-downfeed control.

Using the Fine Downfeed Handwheel

1.

Make sure that the spindle rotation is turned OFF and the spindle is at a complete stop.

2.

To set the downfeed for manual control, pull the downfeed selector knob out, then rotate the selector clockwise until the selector pin seats in the forward manual (disengaged) position.

3.

Set the auto-downfeed direction pin in the neutral (middle) position to disengage the fine downfeed handwheel from the auto downfeed gears.

4.

Position the downfeed stop for the spindle depth that is correct for your operation, then secure it in place with the locking wheel.

5.

Use the coarse downfeed lever to lower the spindle slightly until you can pull the clutch lever out to the left and it locks in place. This will engage the handwheel with the quill and spindle.

6.

To lower the spindle, rotate the fine downfeed handwheel. When the quill dog meets the downfeed stop, the clutch lever will disengage and the spindle will return to the top.

-45-

SB1024/SB1025/SB1026

O P E R A T I O N

For Machines Mfg. Since 8/09

Using the Auto-Downfeed System

When using the auto-downfeed system, the spindle will move in the direction you choose with the auto-downfeed direction pin. When the quill dog reaches the top or meets the downfeed stop, the downfeed clutch lever will release. Then, if the spindle was traveling upward, the movement will simply stop. If the spindle was traveling downward, then the spindle will move back to the top at a rate controlled by the return spring on the left side of the head.

1.

Make sure that the spindle rotation is turned OFF and the spindle is at a complete stop.

4.

Position the auto-downfeed direction pin for the spindle travel that is correct for your operation. It may be necessary to rock the fine downfeed handwheel back-and-forth to move the pin all the way in or out.

Note:

The direction pin has three positions: 1) In for one downfeed direction, 2) middle for

neutral or no movement, and 3) out for the reverse direction. The direction of spindle travel for the in and out positions is relative to the direction of spindle rotation. Keep in mind that spindle rotation and downfeed direction will reverse when the spindle speed range is changed.

2.

To set the mill for auto-downfeed, pull the downfeed selector knob out, then rotate the selector clockwise and seat the pin in the rear auto-downfeed (engaged) position, as illustrated in Figure 42.

5.

Make sure the clutch lever is all the way to

the right in the disengaged position so that the spindle will not travel when rotation is started.

Auto-Downfeed (Engaged) Position Note:

We recommend that you complete the

remaining steps without a cutting tool installed, without a workpiece in place, and the table lower than the maximum spindle downfeed travel. This will enable you to test and confirm the settings before beginning the actual cutting operation.

To avoid damage to the system gearing, never use the auto-downfeed system with spindle speeds over 1860 RPM.

Figure 42. Downfeed selector in the auto-downfeed (engaged) position.

3.

Position the downfeed stop for the spindle depth that is correct for your operation, then secure it in place with the locking wheel.

6.

Set the mill for the correct spindle speed, then begin spindle rotation.

-46-

For Machines Mfg. Since 8/09

O P E R A T I O N

SB1024/SB1025/SB1026

Spindle Brake

To avoid the risk of gear damage, always start spindle rotation before using the auto downfeed rate selector.

7.

Select one of the three downfeed rates by pulling the knob of the auto-downfeed rate selector out, position the selector over the appropriate detent, then release the knob. Make sure the pin is firmly seated by attempting to move the selector without pulling the knob out.

To avoid premature wear of the brake system, use the spindle brake ONLY after power to the spindle has been turned OFF.

After turning the power to the spindle OFF, move the brake lever back or forth to bring the spindle to a full stop (see Figures 44–45).

Note:

Refer to the illustration in Figure 43 when

selecting the downfeed rate.

To evenly wear the brake shoes, alternate the direction you move the lever when braking.

H Model SB1024 Brake Lever L M

H = 0.006 in./rev.

L = 0.0015 in./rev.

M = 0.003 in./rev.

(Rates given in inches of travel per revolution of the spindle)

Figure 43. Positions of the auto-downfeed rate selector.

8.

Use the coarse downfeed lever to lower the spindle slightly until you can pull the clutch lever out to the left and it locks in place, which will start the auto-downfeed spindle travel.

Figure 44. Model SB1024 brake lever location.

Model SB1025/SB1026 Brake Lever Figure 45. Model SB1025/SB1026 brake lever location.

-47-

SB1024/SB1025/SB1026

O P E R A T I O N

For Machines Mfg. Since 8/09

Loading/Unloading Tooling

The mill is equipped with an R8 spindle taper and a 7 ⁄ 16 "-20 x 18 (see Figure 46).

1 ⁄ 2 " spindle drawbar that includes one spacer for tool attachment flexibility

5.

With one hand holding the tool in place, insert the drawbar into the spindle from the top of the head, then thread it into the tool (see Figure 47).

!

Drawbar Spacer Figure 46. Spindle drawbar and spacer.

Tool Needed Qty

Wrench 21mm .......................................................1

Loading Tooling

1.

DISCONNECT MILL FROM POWER!

2.

Clean any debris or surface substances from inside the spindle taper and the mating surface of the tooling.

Note:

Debris or oil substances can prevent the

tooling and spindle from properly mating. This condition can cause excessive vibration, poor cutting results, or tool/workpiece damage.

3.

Place the mill in the low spindle speed range to keep the spindle from turning in the next steps.

4.

Align the keyway of the tool with the protruding pin inside the spindle taper, then firmly push the tool into the spindle to seat it.

Figure 47. Drawbar loading into the spindle (Model SB1025 shown).

6.

Tighten the drawbar until it is snug. Avoid overtightening, as it could make removing the tool difficult.

Unloading Tooling

Tools Needed Qty

Wrench 21mm .......................................................1

Brass Hammer ......................................................1

1.

DISCONNECT MILL FROM POWER!

2.

Place the mill in the low spindle speed range to keep the spindle from turning in the next step.

Note:

Make sure that the drawbar has at least

three threads engaged with the tooling in the next step to avoid damaging the threads of the drawbar or tool.

3.

Loosen the drawbar a couple of turns, then tap the top of it with brass hammer to knock the tool loose at the bottom of the spindle.

4.

Support the tool with one hand, then completely unthread the drawbar.

-48-

For Machines Mfg. Since 8/09 SB1024/SB1025/SB1026

M A I N T E N A N C E

Maintenance Schedule

!

Always disconnect machine from power before performing maintenance or serious personal injury may result.

Each operator of this machine is responsible for ensuring proper care of the equipment. We strongly recommend that all operators make a habit of following the daily maintenance procedures.

For optimum performance from this machine, this maintenance schedule must be strictly followed. Use the Monthly Maintenance Chart on Page 50 to ensure this is done.

Ongoing

To maintain a low risk of injury and proper machine operation, if you ever observe any of the items below shut the machine down immediately, disconnect it from power, and fix the problem before continuing operations.

• Loose mounting bolts or fasteners.

• Worn, frayed, cracked, or damaged wires.

• Emergency STOP button not working correctly.

• Missing belt guards.

• Reduction in braking speed or efficiency.

• Coolant not flowing correctly.

• Any other unsafe condition.

Before Beginning Operations

• Make sure the electric box door is closed and properly latched.

• Turn the spindle direction switch to the off (middle) position to prevent spindle startup when connected to power (see Page 29).

• Move the spindle speed range selector to the manual (forward) position to prevent the spindle from unexpectedly downfeeding when rotation is started (see Page 43).

• Make sure the X-axis power feed is turned OFF to prevent unintentional table movement when connected to power (see

Page 31).

• Check the coolant reservoir in the base for fluid/debris build-up. Clean out if necessary (see Page 56).

• Perform lubrications tasks as directed in the

Lubrication section on Page 51.

• Check table movement in all three axes directions for loose/tight gibs. Adjust the gibs if necessary (see Page 58).

Daily, After Operations

• Push the emergency STOP button and disconnect the machine from power.

• Vacuum/clean all chips and swarf from table, slides, and base.

• Wipe down all unpainted or machined surfaces with a good quality rust preventative.

-49-

SB1024/SB1025/SB1026

M A I N T E N A N C E

For Machines Mfg. Since 8/09 -50 Coolant Reservoir Gib Adjustment Disconnected From Power Cleaned & Protected Table, Saddle, Knee Ways Speed Range Bearing Sleeve Headstock Gearing Table Elevation Leadscrew Power Feed Gears

Use this chart to keep track of the maintenance performed on the mill. Cross out or initial the “Day” box for each item on the list. If the b Make copies of this page to use each month. Keep each charts as a maintenance record for the mill.

For Machines Mfg. Since 8/09

M A I N T E N A N C E

SB1024/SB1025/SB1026

Cleaning

Regular cleaning is one of the most important steps in taking good care of this lathe. Each operator is responsible for cleaning the machine immediately after using it or at the end of the day. We recommend that the cleaning routine be planned into the workflow schedule, so that adequate time is set aside to do the job right.

Typically, the easiest way to clean swarf from the ways and table is to use a wet/dry shop vacuum that is dedicated for this purpose only. The small chips leftover after vacuuming can be wiped up with a slightly oiled rag. Avoid using compressed air to blow off chips, as it may drive them deeper into moving surfaces and could cause sharp chips to fly into your face or hands.

All visible swarf should be removed from the mill during cleaning. Remember, personal neatness gives you personality!

Unpainted & Machined Surfaces

Besides the ways and elevation leadscrew, all other unpainted and machined surfaces should be wiped down daily to keep them rust-free and in top condition. This includes surface you can find that could be vulnerable to rust if left unprotected (this especially includes any parts that may be exposed to water soluble cutting fluids). Typically with these parts, a thin film of oil is all that is necessary for protection.

Lubrication

The mill has numerous moving metal-to metal contacts that require regular and proper lubrication to ensure efficient and long-lasting operation, and to protect your investment.

Other than the lubrication points covered in this section, all other bearings are internally lubricated and sealed at the factory. Simply leave them alone unless they need to be replaced.

Before performing any lubrication task, DISCONNECT THE MILL FROM POWER!

Important: Before adding lubricant, clean the

debris and grime from the oil cup or grease fitting and the immediate area to prevent contamination of the oil cups, grease fittings, or new lubricant.

Use the schedule and information in Figure 48 as a daily guide for lubrication tasks. Follow the referenced sections on the following pages for detailed instructions.

The following recommended lubrication schedule is based on light to medium mill usage. Keeping in mind that lubrication helps to protect the value and operation of the mill, you may need to perform the lubrication tasks more frequently depending on your usage.

Lubrication Task

Quill Table Ways (One-Shot Oiler) Speed Range Bearing Sleeve (SB1024 Only) Headstock Gearing

Frequency (Hours of Operation)

4 hrs.

4–8 hrs.

40 hrs.

40 hrs.

Page Ref.

52 52 53 53 Ram Ways Table Elevation Leadscrew (Z-Axis) 40 hrs.

40 hrs.

54 54 Power Feed Gears 160 hrs.

Figure 48. Recommended lubrication tasks, schedules, and instruction page references.

54 -51-

SB1024/SB1025/SB1026

M A I N T E N A N C E

For Machines Mfg. Since 8/09

Failure to follow reasonable lubrication practices as instructed in this manual for the mill could lead to premature failure of the mill and will void the warranty.

Quill

Oil Type ...... Mobil Vactra 2 or ISO 68 Equivalent Oil Amount .......................................... Fill Oil Cup Check/Add Frequency ..............4 hrs. of Operation Lift the oil cup cap shown in Figure 49 to add 10 drops of lubricant.

Table Ways (One-Shot Oiler)

Oil Type ...... Mobil Vactra 2 or ISO 68 Equivalent Oil Amount ................... One Pull of Pump Handle Check/Add Frequency ..........4–8 hrs. of Operation The one-shot oiler is connected to a series of aluminum tubes that carry the lubricant to wear points along the table horizontal and vertical ways. After using the oiler pump handle shown in Figure 50, move the table through all paths of movement to evenly distribute the lubricant.

Use the sight glass on the side of the oiler to know when to re-fill the reservoir.

Reservoir Cap Pump Handle Quill Oil Cup Figure 49. Quill oil cup location.

Sight Glass Figure 50. One-shot oiler controls.

-52-

For Machines Mfg. Since 8/09

M A I N T E N A N C E

SB1024/SB1025/SB1026

Speed Range Bearing Sleeve (SB1024 Only)

Oil Type ...... Mobil Vactra 2 or ISO 68 Equivalent Oil Amount .......................................... Fill Oil Cup Check/Add Frequency ............40 hrs. of Operation Lift the oil cup cap shown in Figure 51 to add 5 drops of lubricant.

Headstock Gearing

Grease Type .........................NLGI 2 or Equivalent Grease Amount ...........Two Pumps of Grease Gun Check/Add Frequency ............40 hrs. of Operation Add two pumps from a grease gun to the grease fitting for the mill that is shown in

Figures 52–53.

Oil Cup Figure 51. Speed range bearing sleeve (SB1024 only).

SB1024 Grease Fitting Figure 52. SB1024 headstock gearing grease fitting.

SB1025/SB1026 Grease Fitting Figure 53. SB1025/SB1026 headstock gearing grease fitting.

-53-

SB1024/SB1025/SB1026

M A I N T E N A N C E

For Machines Mfg. Since 8/09

Ram Ways

Oil Type ...... Mobil Vactra 2 or ISO 68 Equivalent Oil Amount ............................................. Thin Coat Check/Add Frequency ............40 hrs. of Operation Move the ram back and forth as necessary to access the full length of the ways (see

Figure 54), then use a clean shop rag to apply a

thin coat of lubricant.

Table Elevation Leadscrew

Grease Type .........................NLGI 2 or Equivalent Grease Amount ...................................... Thin Coat Check/Add Frequency ............40 hrs. of Operation Elevate the table all the way up, then use mineral spirits to clean any debris and built-up grime from the elevation leadscrew threads. Add one pump from a grease gun to the leadscrew grease fitting shown in Figure 56, then run the knee up and down to distribute the grease. Repeat this process until the entire leadscrew

Ram Ways Leadscrew Grease Fitting Figure 54. Exposing the ram ways for lubrication.

Head & Ram Rack & Pinion Gear

The interaction between the cast iron surfaces of these devices (see Figure 55) produces a dry powder that provides an adequate lubrication.

Do not apply any other lubricant which could produce a stiff compound that may interfere with smooth movement.

Head Rack & Pinion Gear Ram Pinion Gear Figure 56. Table elevation leadscrew and grease fitting.

Power Feed Gears

Grease Type .......Medium-Weight Lithium Grease Grease Amount ...........Two Pumps of Grease Gun Check/Add Frequency ............40 hrs. of Operation

Tool Needed Qty

Wrench 19mm .......................................................1

To lubricate the power feed gears:

1.

DISCONNECT MACHINE FROM POWER!

Ram Rack Figure 55. Locations of head and ram rack and pinion gears.

-54-

For Machines Mfg. Since 8/09

M A I N T E N A N C E

SB1024/SB1025/SB1026

2.

Remove the hex nut and ball handle from the power unit end of the longitudinal leadscrew (see Figure 57).

5.

Brush a light coat of lubricant on the teeth of the bevel gear and the smaller drive gear (see Figure 59).

Graduated Dial Ring Leadscrew Retaining Ring Figure 57. Power feed ball handle removed.

3.

Unthread and remove the knurled retaining ring and graduated dial ring from the end of the leadscrew.

4.

Remove the brass bevel gear from the leadscrew, then remove the leadscrew alignment key (see Figure 58).

Alignment Key Drive Gear Bevel Gear Figure 59. Power feed brass gear and drive gear.

6.

Replace the leadscrew alignment key, then

align the bevel gear keyway and the key as you slide the gear onto the leadscrew and mesh its teeth with the drive gear.

7.

Replace the graduated dial ring into position and secure it with the knurled retaining ring—do not overtighten.

8.

Slide the ball handle onto the leadscrew as you align its keyway with the leadscrew alignment key, then secure it with the hex nut removed in Step 2.

9.

Manually move the table with the power feed ball handle to check the gear movement and to distribute the grease on the gears. If the movement is not smooth, repeat Steps 2–8 until it is.

Brass Bevel Gear Figure 58. Power feed brass gear and leadscrew alignment key.

-55-

SB1024/SB1025/SB1026

Cleaning Coolant Reservoir

M A I N T E N A N C E BIOLOGICAL & POISON HAZARD!

Use the correct personal protection equipment when handling cutting fluid. Follow Federal, State, and the coolant manufacturer's requirement to safely dispose of the used coolant.

Cleaning

Tools Needed Qty

Hex Wrench 3mm .................................................1

Hex Wrench 10mm ...............................................1

Catch Pan ..............................................................1

To clean out the coolant reservoir:

1.

DISCONNECT MILL FROM POWER!

2.

Put on personal protective equipment.

3.

Remove the coolant reservoir access panel from the rear of the column (see Figure 60).

Screen

For Machines Mfg. Since 8/09 The cavity in the base of the mill can be used as a coolant reservoir if you choose to install a recirculating coolant pump accessory. This reservoir also catches any coolant and debris that falls from the table and through the screens in the base.

Hazards

As some coolant ages, it develops dangerous microbes which eventually proliferate and create a biological hazard. The risk of exposure to this hazard can be greatly reduced by cleaning out the coolant reservoir on a monthly basis or sooner, if needed based on your daily inspection.

The important thing to keep in mind when working with coolant is to minimize exposure to your skin, eyes, and respiratory system by wearing the proper personal protective equipment, which includes splash-resistant safety glasses, long-sleeve gloves, protective clothing, and a NIOSH-approved respirator.

Access Panel Drain Plug Figure 60. Coolant reservoir access panel and drain plug.

4.

Place the catch pan under the drain plug, then remove the plug and allow the fluid to drain into the pan.

5.

Clean away debris and grime from the coolant drain screens on the base of the mill.

6.

Use rags, scrapers, and cleaning solvent to thoroughly clean out the bottom of the reservoir.

Note:

Use a cleaning solvent that is compatible

with the type of coolant. For instance, if you are using a water-base coolant, then use a water-base cleaning solvent.

7.

When the reservoir is clean and dry, replace the access panel and drain plug.

-56-

For Machines Mfg. Since 8/09

M A I N T E N A N C E

SB1024/SB1025/SB1026

Machine Storage

To avoid rust problems or corrosion damage, use the following information to protect your investment when storing the mill for any length of time.

• DISCONNECT MILL FROM POWER!

• Lubricate the mill as directed in the

Lubrication section beginning on Page 51.

• Clean out the coolant reservoir in the base of the mill as directed in the Cleaning

Coolant Reservoir section on Page 56.

• Thoroughly clean all unpainted, bare metal surfaces, then coat them with a light weight grease or rust preventative. Take care to ensure these surfaces are completely covered but that the grease or rust preventative is kept off painted surfaces.

Note:

If the machine will be out of service for only a short period of time, use way oil or a good grade of medium-weight machine oil (not auto engine oil) in place of the grease or rust preventative.

• Loosen the belts to prevent them from stretching during storage. Post a reminder on the mill that the belts need to be re installed or tensioned before resuming operations.

• Place a few moisture absorbing desiccant packs inside the electrical and control panel boxes.

• Cover and place the machine in a dry area that is out of direct sunlight and away from hazardous fumes, paint, solvents, or gas. Fumes and sunlight can bleach or discolor paint and plastic parts.

• At least once a month, start the mill and run all gear-driven components for a few minutes. This will keep the bearings, bushings, gears, and shafts well lubricated and protected from corrosion, especially during the winter months.

-57-

SB1024/SB1025/SB1026

S E R V I C E

For Machines Mfg. Since 8/09

Adjusting Gibs

Gibs are tapered lengths of metal that are sandwiched between two moving surfaces. Gibs control the gap between these surfaces and how they slide past one another. Correctly adjusting the gibs is critical to producing good milling results.

Tight gibs make table movement more accurate but stiff. Loose gibs make moving the table sloppy but easier to do. The goal of gib adjustment is to remove unnecessary sloppiness without causing the ways to bind.

Gibs are adjusted with a screw on each end of the gib, that move the tapered gib back-and forth to increase or decrease the friction pressure between the sliding surfaces. The process of properly adjusting the gibs requires trial-and error and patience.

DISCONNECT MILL FROM POWER BEFORE ADJUSTING THE GIBS!

Make sure all table and knee locks are loose. Then, loosen one gib adjustment screw and tighten the other the same amount to move the gib. Use the ball handles/crank to move the table/ knee until you feel a slight drag in that path of movement.

Refer to Figures 61–63 to identify the locations of the table, saddle, and knee gibs, and one of the two adjustment screws for each.

Note:

It will be necessary to remove small parts,

such as way wipers and covers, to access the gib adjustment screws.

Table Gib & Adjustment Screw Figure 61. Table gib and adjustment screw underneath the left side of the table.

Saddle Gib & Adjustment Screw Figure 62. Saddle gib and adjustment screw.

Knee Gib & Adjustment Screw Figure 63. Knee gib and adjustment screw.

-58-

For Machines Mfg. Since 8/09

S E R V I C E

SB1024/SB1025/SB1026

Adjusting Leadscrew Backlash

Leadscrew backlash is the amount of motion the leadscrew rotates before the attached device begins to move.

Although the mill is equipped with double bronzed longitudinal and cross leadscrew nuts to minimize backlash, leadscrews will always have a certain amount of backlash that will increase with normal wear.

Generally, 0.005"–0.010" leadscrew backlash is acceptable to ensure smooth movement and reduce the risk of premature thread wear. However, if you find it necessary to adjust leadscrew backlash, perform the procedures listed below.

Tools Needed Qty

T-Handle Hex Wrench 5mm .................................1

Hex Wrench 3mm .................................................2

Hex Wrench 8mm .................................................1

Wrench 19mm .......................................................1

Longitudinal Leadscrew Backlash

1.

DISCONNECT MILL FROM POWER!

2.

Loosen the two cap screws on the leadscrew nut accessed from underneath the left side of the table, as shown in Figure 64.

Leadscrew Nut (1 of 2) & Cap Screw Figure 64. Longitudinal leadscrew nut and cap screw, as viewed from underneath the left side of the table.

3.

Rotate the adjustment plate on the leadscrew nut in small increments, then check the amount of backlash.

4.

When you are satisfied with the adjustment, re-tighten the two cap screws.

-59-

SB1024/SB1025/SB1026

S E R V I C E

Cross Leadscrew Backlash

1.

DISCONNECT MILL FROM POWER!

2.

Remove the hex nut and ball handle from the cross leadscrew.

Note:

In the next step, take care not to misplace

the leadscrew key as you remove the parts.

3.

Unthread and remove the knurled retaining ring, graduated dial ring, and the leadscrew key, as shown in Figure 65.

Bearing Housing

For Machines Mfg. Since 8/09

Figure 66. Removing the bearing housing from the cross leadscrew.

5.

Loosen the two cap screws on the face of the leadscrew nut shown in Figure 67.

Cross Leadscrew Figure 65. Ball handle, rings, and key removed from the cross leadscrew.

4.

Remove the four cap screws from the bearing housing, then slide it off the leadscrew (see

Figure 66).

Note:

It may be necessary to use a dead blow

hammer or rubber mallet on the housing to knock it loose.

Cross Leadscrew Nut & Cap Screws Figure 67. Cross leadscrew nut and cap screws.

6.

Re-install the key back onto the leadscrew so that you can use the ball handle in the next step.

7.

Rotate the adjustment plate on the leadscrew nut in small increments, then check the amount of backlash.

8.

When you are satisfied with the adjustment, re-tighten the two cap screws.

9.

Re-install the parts previously removed in the reverse order.

-60-

For Machines Mfg. Since 8/09

TROUBLESHOOTING

SB1024/SB1025/SB1026 If you need replacement parts, or if you are unsure how to do any of the solutions given here, feel free to call us at (360) 734-1540.

!

Symptom Possible Cause Possible Solution

Machine does not start or a breaker trips.

Machine stalls or is overloaded.

1.

2.

3.

4.

5.

6.

Emergency stop button is pushed in or is at fault.

Plug/receptacle is at fault or wired incorrectly.

Power supply is switch OFF or is at fault.

Motor connection wired incorrectly.

ON button or spindle direction switch at fault.

Motor windings or motor is at fault.

1.

Machine is undersized for the task.

2.

Workpiece alignment is poor.

3.

4.

5.

6.

7.

8.

Dull or incorrect cutting tool.

Spindle speed is incorrect for the operation.

Motor connection wired incorrectly.

Plug/receptacle is at fault or wired incorrectly; incorrect voltage coming from power source.

Pulley(s) slipping on shaft.

Motor bearings at fault.

9.

10.

Motor has overheated.

Motor is at fault.

1.

2.

Rotate the button clockwise until it pops out; replace if necessary.

Test for good contacts; correct the wiring.

3.

4.

5.

6.

Ensure hot lines have correct voltage on all legs and main power supply is switched ON.

Correct motor wiring connections (Pages 66 & 69).

Replace faulty ON button or spindle direction switch.

Replace motor.

1.

2.

3.

4.

Use smaller sharp tooling; reduce the feed rate; reduce the spindle speed; use coolant.

Eliminate workpiece binding; use vise or clamps as required for proper workpiece alignment control.

Use sharp and correct cutting tool for the operation.

Select appropriate spindle speed (Page 37).

5.

6.

Correct motor wiring connections (Pages 66 & 69).

Test for good contact; correct wiring problems; ensure hot lines have correct voltage on all legs.

7.

8.

9.

10.

Replace loose pulley/shaft.

Test by rotating shaft; rotation grinding/loose shaft requires bearing replacement.

Clean off motor, let cool, and reduce workload.

Replace motor.

Machine has vibration or noisy operation.

1.

Tool holder or cutter is at fault.

2.

Workpiece alignment is poor.

3.

Motor or component is loose.

4.

Pulley is loose.

6.

7.

8.

5.

Machine is incorrectly mounted to floor or sits uneven.

Motor fan is rubbing on fan cover.

Pulley(s) slipping on shaft.

Motor bearings at fault.

9.

Gearbox is at fault.

1.

2.

3.

4.

5.

6.

7.

8.

9.

Replace out-of-round tool holder; replace/re-sharpen cutter; use appropriate feed rate spindle speed.

Eliminate workpiece binding; use vise or clamps as required for proper workpiece alignment control.

Inspect replace stripped or damaged bolts/nuts and re-tighten with thread locking fluid.

Re-align/replace shaft, pulley, set screw, and key as required.

Re-tighten/replace mounting bolts in floor; relocate/ shim machine.

Replace dented fan cover or fan.

Replace loose pulley/shaft.

Test by rotating shaft; rotation grinding/loose shaft requires bearing replacement.

Rebuild gearbox for bad gear(s)/bearing(s).

-61-

SB1024/SB1025/SB1026

Symptom

Tool slips in collect.

TROUBLESHOOTING Possible Cause 1.

2.

3.

4.

Collet is not fully drawn into spindle taper.

Wrong size collet.

Debris on mating surfaces of collet and spindle.

Excessive depth of cut.

For Machines Mfg. Since 8/09

!

Possible Solution 1.

Snug up the drawbar to fully seat the collet.

2.

3.

4.

Use correct collect for tool shank diameter.

Remove oil and debris from mating surfaces, then re-install.

Decrease depth of cut and allow chips to clear.

Tool breakage.

1.

2.

Spindle speed too slow/feed rate too fast.

Tool getting too hot.

1.

Use correct spindle speed and feed rate (Page 37).

Workpiece chatters or vibrates during operation.

Table hard to move.

Bad surface finish.

3.

Excessive depth of cut.

1.

Table/saddle/knee locks not tight.

2.

Workpiece not securely clamped to table or mill vise.

3.

4.

5.

Tool not secure or is damaged.

Spindle speed too fast/feed rate too slow.

Gibs are too loose.

1.

2.

Table/saddle/knee locks are tightened down.

Chips have loaded up on the ways.

3.

4.

Ways are dry and in need of lubrication.

Gibs are too tight.

1.

2.

3.

4.

Wrong spindle speed/feed rate.

Dull/damaged tool; wrong tool for operation.

Wrong spindle rotation direction for tool.

Workpiece not securely clamped to table or mill vise.

2.

3.

Use coolant; reduce spindle speed/feed rate (Page 37).

Decrease depth of cut and allow chips to clear.

1.

2.

3.

4.

Tighten all locks on mill that are not associated with necessary table movement for the operation.

Check that clamping is tight and sufficient for the operation; make sure mill vise is clamped tight to table.

Properly secure the tool; replace if damaged.

Use correct spindle speed and feed rate (Page 37).

5.

Properly adjust gibs (Page 58).

1.

Full loosen locks needed for movement.

2.

3.

Frequently clean away chips from the ways that build up during operation.

Use the one-shot oiler (Page 52).

4.

Properly adjust gibs (Page 58).

1.

2.

Use correct spindle speed and feed rate (Page 37).

Sharpen/replace tool; use correct tool for operation.

3.

Check for proper spindle rotation direction for tool.

Power feed chatters or grinds during operation.

5.

Gibs are too loose.

1.

Brass bevel gear is not meshed with the drive gear.

2.

Power feed unit is at fault

4.

5.

Check that clamping is tight and sufficient for the operation; make sure mill vise is clamped tight to table.

Properly adjust gibs (Page 58).

1.

2.

Remove parts from the power feed side of the longitudinal leadscrew to ensure the bevel gear is properly meshed; make sure the ball handle nut is tight.

Replace.

-62-

For Machines Mfg. Since 8/09

E L E C T R I C A L

SB1024/SB1025/SB1026

Electrical Safety Instructions

These pages are accurate at the time of printing. In the constant effort to improve, however, we may make changes to the electrical systems of future machines. Study this section carefully. If you see differences between your machine and what is shown in this section, call Technical Support at (360) 734-1540 for assistance BEFORE making any changes to the wiring on the machine.

1. Shock Hazard:

Working on wiring that is connected to a power source is extremely dangerous. Touching electrified parts will result in personal injury including but not limited to severe burns, electrocution, or death. Disconnect the power from the machine before servicing electrical components!

2. Wire Connections:

All connections must be tight to prevent wires from loosening during machine operation. Double-check all wires disconnected or connected during any wiring task to ensure tight connections.

3. Modifications:

Using aftermarket parts or modifying the wiring beyond what is shown in the diagram may lead to unpredictable results, including serious injury or fire.

5. Circuit Requirements:

the requirements at the beginning of this manual when connecting your machine to a power source.

You MUST follow

6. Capacitors/Inverters:

Some capacitors and power inverters store an electrical charge for up to 10 minutes after being disconnected from the power source. To reduce the risk of being shocked, wait at least this long before working on capacitors.

7. Wire/Component Damage:

completing the task.

Damaged wires

or components increase the risk of serious personal injury, fire, or machine damage. If you notice that any wires or components are damaged while performing a wiring task, replace those wires or components before

4. Motor Wiring:

The motor wiring shown in these diagrams is current at the time of printing, but it may not match your machine. Always use the wiring diagram inside the motor junction box.

8. Experiencing Difficulties:

If you are experiencing difficulties understanding the information included in this section, contact our Technical Support at (360) 734-1540.

-63-

SB1024/SB1025/SB1026

Wiring Overview

E L E C T R I C A L

For Machines Mfg. Since 8/09

Motor Junction Box SB1024/SB1026: See Page 66 and Figure 70 SB1025: See Page 69 and Figure 74 Work Lamp SB1024/SB1026: See Page 66 and Figure 69 SB1025: See Page 69 and Figure 73

-64-

Control Panel SB1024/SB1026: See Page 66 and Figure 71 SB1025: See Page 69 and Figure 75 Electrical Box SB1024/SB1026: See Page 65 and Figure 68 SB1024/SB1026: See Page 68 and Figure 72

WIRING DIAGRAM COLOR KEY

BLACK BLUE BROWN

NOTICE:

BLUE WHITE GREEN RED LIGHT BLUE PINK PURPLE WHITE YELLOW GREEN GRAY ORANGE TUR QUIOSE YELLOW The photos and diagrams included in this section are best viewed in color. You can see them in color at www.southbendlathe.com.

For Machines Mfg. Since 8/09

E L E C T R I C A L

SB1024/SB1026 Electrical Box

T R 0V 230V 380V 415V 460V TRANSFORMER Yung-Jeng A009-0383 110V 24V 12V 0V E T1 1R 3R L1 Fuse 30A R Fuse 30A T 3R 3R 3R 1R 35 1 20

SB1024/SB1025/SB1026

SB1024/26 Electrical Box, See Figure 71 R A1 R R T T T1 A2 1 L1 3 L2 5 L3 21 NC T1 T1 11 R A1 T A2 9 T 1 L1 3 L2 5 L3 21 NC CONTACTOR Allen Bradley C16 01 2 T1 4 T2 6 T3 22 NC CONTACTOR Allen Bradley C16 01 2 T1 4 T2 6 T3 22 NC U V W 10 U V W 8 2 T1 T1 20 A1 T1 A2 1 L1 3 L2 5 L3 7 L4 CONTACTOR Allen Bradley C09 400 2 T1 4 T2 6 T3 8 T4 3 RELAY OMRON MY2J 24VAC 21 22 4 4 T1 T1 W V U 1 2 3 4 8 10 21 22 35 T1 1 2 3 4 10 8 T1 2 3 4 8 10 21 21 22 22 35 T1 T1 35 T1 Ground U V W L1 L3 U V W L1 L3 22 21 21 22 L1 L3

-65-

SB1024/SB1025/SB1026

E L E C T R I C A L

For Machines Mfg. Since 8/09

SB1024/SB1026 Electrical Components

Motor See Figure 70 Work Lamp See Figure 69 Ground U V W Ground G Hot 220 VAC Hot 6-20 Plug (As Recommended) Control Panel (Viewed From Behind) See Figure 71 Power Indicator Emergency Stop T1 X1 X2 1 1 1 1 2 2 2 Spindle Start 4 X1 X2 4 3 4 4 3 T1 T1 Spindle Stop 3 3 1 2 2 4 3 4 8 4 3 4 10 Spindle Direction 10 T1 4 2 8 3 1

-66-

For Machines Mfg. Since 8/09

E L E C T R I C A L

SB1024/SB1025/SB1026

SB1024/SB1026 Electrical Component Pictures

Figure 70. Motor junction box.

Figure 68. Electrical box.

Figure 71. Control panel.

Figure 69. Work lamp.

-67-

SB1024/SB1025/SB1026

E L E C T R I C A L

SB1025 Electrical Box

T R L1 L2 L3 0V 230V 380V 415V 460V TRANSFORMER Yung-Jeng A009-0383 110V 24V 12V 0V E 1R 3R T1 Fuse 20A Fuse 20A Fuse 20A R R S T T

For Machines Mfg. Since 8/09

3R 3R 3R R 35 1 20 Electrical Box, See Figure 72 4 4 T1 R A1 S T A2 4 1 L1 3 L2 5 L3 7 L4 2 20 A1 T1 T1 T1 A2 1 L1 3 L2 5 L3 7 L4 CONTACTOR Allen Bradley C09 400 CONTACTOR Allen Bradley C09 400 2 T1 4 T2 6 T3 8 T4 U V W 3 2 T1 4 T2 6 T3 8 T4 21 22 U1 V1 W1 U2 V2 W2 U1 V1 W1 U2 V2 W2 U2 W1 V1 W1 V2 W2 1 2 3 4 21 22 35 T1 U V W L1 L2 L3 W2 W1 U2 V2 V1 U1 3 4 1 2 T1 Ground 1 2 3 4 21 21 22 22 35 T1 T1 35 T1 U V W L1 L2 L3 21 22 21 22 L1 L2 L3

-68-

For Machines Mfg. Since 8/09

E L E C T R I C A L

SB1025 Electrical Components

Motor See Figure 74 Work Lamp See Figure 73

SB1024/SB1025/SB1026

Ground U2 U2 V2 V2 W2 W2 U1 U1 V1 V1 W1 W1 Ground Hot Hot Hot

220 VAC L15-20 PLUG (as recommended)

Power Indicator T1 Spindle Start 4 4 1 2 X1 X2 3 4 1 T1 T1 3 Emergency Stop 1 1 Spindle Stop 3 3 2 1 1 2 GND 2 2 2 Control Panel (Viewed From Behind) See Figure 75 Spindle Direction/Speed Switch (Both Sides Shown) V2 V1 4 1 8 5 12 9 16 13 20 17 24 21 U V U2 U1 W 2 3 6 7 10 11 14 15 18 19 22 23 W1 W2 U2 V1 W V 3 2 4 U U1 1 V2 T1

-69-

SB1024/SB1025/SB1026

E L E C T R I C A L

For Machines Mfg. Since 8/09

SB1025 Electrical Component Pictures

-70-

Figure 74. SB1025 Motor junction box.

Figure 72. SB1025 Electrical box.

Figure 75. SB1025 Control panel.

Figure 73. SB1025 Work lamp.

For Machines Mfg. Since 8/09

Headstock

P A R T S

SB1024/SB1025/SB1026 104 105 -71-

SB1024/SB1025/SB1026

Headstock Parts List

REF PART # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 41 42 43 44 45 46 34 35 36 37A 37 38 39 40 47 48 49 DESCRIPTION PSB10240449 ROUND KNOB 3/8-16 PSB10240002 PINION SHAFT LEVER PSB10240003 PINION SHAFT HUB PSTB004 STEEL BALL 3/16 PSB10240005 COMPRESSION SPRING PSS05 PSB10240007 SET SCREW 5/16-18 X 1/4 HUB RETAINER PSB10240008 PINION SHAFT HUB SLEEVE PCAP33M PSB10240010 CAP SCREW M5-.8 X 12 RETURN SPRING COVER PSB10240011 PK155M PSB10240013 PSB10240014 PRIV001M PSB10240017 PSB10240018 PSB10240019 PSS11 PSB10240021 PSB10240022 FLAT COIL SPRING KEY 3 X 3 X 18 RETURN SPRING STUD QUILL PINION SHAFT 10T/16T FLUTED RIVET 2 X 5MM STEEL ZERO SCALE ROUND KNOB 1/4-20 SHIFT CRANK SET SCREW 1/4-20 X 1/4 COMPRESSION SPRING 9 X 1 X 24MM GEAR SHIFT PLUNGER PSB10240023 PSB10240024 PSB10240025 SHIFT SLEEVE WORM GEAR CRADLE THROW-OUT WORM SHAFT PSS01M PK102M SET SCREW M6-1 X 10 KEY 4 X 4 X 18 PSB10240028 WORM GEAR PSB10240029 CLUSTER GEAR RETAINER PSB10240030 FEED CLUSTER GEAR 17T/28T/22T PR06M EXT RETAINING RING 16MM PSB10240032 BEVEL GEAR BUSHING PSB10240033 BEVEL GEAR THRUST SPACER PSB10240034 PK53M FEED REVERSE BEVEL PINION KEY 3 X 3 X 45 PSB10240037A FEED ENGAGE PIN PSB10240037A WORM GEAR CRADLE ASSEMBLY PSB10240037A WORM GEAR CRADLE PSS26M SET SCREW M5-.8 X 6 PCAP04M PW03M CAP SCREW M6-1 X 10 FLAT WASHER 6MM PSB10240037A WORM GEAR SPACER PSB10240037A FEED DRIVE WORM GEAR 20T PSB10240037A WORM CRADLE BUSHING PK103M KEY 3 X 3 X 12 PSB10240037A FEED REVERSE BEVEL PINION PCAP30 CAP SCREW 5/16-18 X 1/2 PSB10240037A BEVEL GEAR FLAT WASHER 8MM PSB10240037A FEED BEVEL GEAR 24T PK03M KEY 3 X 3 X 8

P A R T S

For Machines Mfg. Since 8/09 REF PART # 50 51 52 53 54 55A 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 75 76 77 78 79 70 71 72 73 73A 74 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 DESCRIPTION PSB10240037A CLUSTER GEAR SHAFT 18T/12T PSB10240037A FEED DRIVE CLUSTER GEAR 23T PSB10240037A NEEDLE BEARING BZ66Z TIMKEN PSB10240053 REVERSE CLUTCH ROD PSB10240055A FEED REVERSE BUSHING PSB10240055A FEED REVERSE BEVEL GEAR ASSY PSB10240055A FEED REVERSE BEVEL GEAR PSB10240056 FEED REVERSE CLUTCH PRP42M PR03M ROLL PIN 3 X 20 EXT RETAINING RING 12MM PSB10240059 FEED WORM SHAFT BUSHING PK39M KEY 3 X 3 X 10 PK52M KEY 3 X 3 X 15 PSB10240062 WORM PSB10240063 BUSHING PCAP06M CAP SCREW M6-1 X 25 PSS01M SET SCREW M6-1 X 10 PSB10240066 FEED GEAR SHIFTER FORK PSB10240067 CLUSTER GEAR SHIFT CRANK PSB10240068 FEED SHIFT ROD PSB10240069 CLUSTER GEAR COVER PSB10240070 PSB10240071 PR05M QUILL PINION SHAFT BUSHING OVERLOAD CLUTCH WORM GEAR 30T EXT RETAINING RING 15MM PSB10240073A PINION OVERLOAD CLUTCH SHAFT PSB10240073A PINION OVERLOAD CLUTCH ASSY PSB10240073A OVERLOAD CLUTCH PSB10240073A COMPRESSION SPRING 40 X 46 X 3.5MM

PSS05M SET SCREW M5-.8 X 10 PSB10240073A PINION OVERLOAD CLUTCH COLLAR PSB10240078 PSB10240079 CLUTCH RING FLAT WASHER 10 X 22 X 3MM PR01M PSB10240081 EXT RETAINING RING 10MM CLUTCH RING SCREW M5-.8 X 16 PSB10240082 OVERLOAD CLUTCH TRIP LEVER PRP03M ROLL PIN 5 X 20 PSB10240084 CLUTCH ARM COVER PCAP79M CAP SCREW M5-.8 X 35 PN05 PSS06 HEX NUT 1/4-20 SET SCREW 1/4-20 X 3/4 PSB10240088 COMPRESSION SPRING 1.2 X 6.6 X 42MM PSB10240089 OVERLOAD CLUTCH PLUNGER PSB10240090 OIL CUP 1/8" PSB10240091 PSB10240092 TRIP PLUNGER BUSHING FEED TRIP PLUNGER PSB10240093 FEED TRIP LEVER PSB10240094 TRIP LEVER SCREW M6-1 X 22.5

PN04M HEX NUT M4-.7

PSS49M SET SCREW M4-.7 X 16 -72-

For Machines Mfg. Since 8/09

Headstock Parts List

REF PART # DESCRIPTION 97 98 99 100 PSB10240097 KNURLED KNOB SCREW M6-1 X 15 PSB10240098 SCRIBING LEVER PSB10240099 REVERSE TRIP BALL LEVER SCREW PSB10240100 FEED REVERSE TRIP PLUNGER 101 102 103 PSB10240101 PSB10240102 REVERSE TRIP BALL LEVER QUILL STOP KNOB PSB10240105A UPPER QUILL MICRO STOP 104 PSB10240105A LOWER QUILL MICRO STOP 105A PSB10240105A QUILL MICRO STOP ASSEMBLY 105 PSB10240105A QUILL MICRO STOP SHAFT 110 111 112 113 114 115 106 PCAP105 CAP SCREW 3/8-16 X 5/8 107A PSB10240107A STOP TRIP BAR ASSEMBLY 107 PSB10240107A STOP SHAFT TRIP BAR 108 109 PSB10240107A COMPRESSION SPRING PSB10240107A STOP SHAFT TRIP SHAFT PRP61M PRP02M ROLL PIN 3 X 12 PSB10240107A STOP SHAFT END CAP ROLL PIN 3 X 16 PSB10240107A TRIP BAR SET SCREW PSB10240107A STOP SHAFT PLUNGER PSB10240115 FEED TRIP BRACKET

P A R T S

SB1024/SB1025/SB1026 REF PART # DESCRIPTION 116 117 118 119 120 121 122 123 124 125 PCAP02M PSB10240117 PSB10240118 PSTB004M PSB10240120 PSS17M PSB10240122 PS17M PSB10240124 PSB10240125 CAP SCREW M6-1 X 20 STOP SHAFT TRIP LEVER HANDWHEEL CLUTCH STEEL BALL 5MM COMPRESSION SPRING SET SCREW M8-1.25 X 6 QUILL DEPTH SCALE PHLP HD SCR M4-.7 X 6 FINE DOWNFEED HANDWHEEL HANDWHEEL HANDLE 126 PEC13M E-CLIP 5MM 127A PSB10240127A KNURLED SLEEVE ASSEMBLY 129 PSB10240129 QUILL LOCK NUT M18-2.5

130 PSB10240130 QUILL LOCK SLEEVE 133A PSB10240133A LOCK HANDLE ASSEMBLY 135 136 137 138 139 PSB10240135 PSB10240136 PSB10240137 PSB10240138 PSB10240139 HEAD ROTATION LOCK BOLT 1/2-13 X 6-1/4 LOWER CLAMPING BOLT SPACER LOCK BOLT FLAT WASHER LOCK BOLT HEX NUT 1/2-13 QUILL HOUSING -73-

SB1024/SB1025/SB1026

Quill

P A R T S

For Machines Mfg. Since 8/09 Quill Housing 217 216 215 218 214 213 212 211 210 209 208 205 207 206 205 204 203 206A 202 201 REF PART # DESCRIPTION 201 202 203 204 PSB10240201 PSS03M PSB10240203 PSB10240204 SPINDLE R8 SET SCREW M6-1 X 8 QUILL END CAP QUILL SEAL 205 PSB10240205 ANGULAR CONTACT BEARING 7207 P4 206A PSB10240206A BEARING SPACER ASSEMBLY 206 PSB10240206A BEARING SPACER 207 208 209 PSB10240206A BEARING SPACER PSB10240208 SLEEVE P6206ZZ BALL BEARING 6206ZZ REF PART # 210 211 212 213 214 215 216 217 218 PSB10240210 PSB10240211 PSB10240212 PSS26M PSB10240214 PW02M PS09M PSB10240217 PSB10240218 DESCRIPTION SPANNER LOCK WASHER SPANNER NUT QUILL SKIRT SET SCREW M5-.8 X 6 QUILL FLAT WASHER 5MM PHLP HD SCR M5-.8 X 10 DRAWBAR 7/16-20 X 18-1/2 DRAWBAR WASHER -74-

For Machines Mfg. Since 8/09

SB1024 Gearbox

P A R T S

303A 302 304 301 316 317 For Reference Only 303 314 315 312 318 SB1024/SB1025/SB1026 305 324 325 306 307 308 307A 306 309 310 331 311 333 313 334 332 326 327 328 329 330 329 335 321 322 323 336 337 341 342 339 340 346 347 343 344 345 348 349 -75-

SB1024/SB1025/SB1026

P A R T S

For Machines Mfg. Since 8/09

SB1024 Gearbox Parts List

REF PART # DESCRIPTION 307 308 309 310 311 312 313 314 315 316 317 318 321 322 323 324 301 PSB10240301 GEARBOX PLATE 302 PK70M KEY 8 X 8 X 12 303A PSB10240303A SPINDLE GEAR HUB ASSEMBLY 303 304 305 PSB10240303A SPINDLE GEAR HUB PSB10240304 PSB10240305 SPINDLE BULL GEAR BEARING SLEAVE 306 P6908VV-N DEEP GROOVE BALL BEARING 6908VV NSK 307A PSB10240307A BEARING SPACER ASSEMBLY PSB10240307A BULL GEAR BEARING SPACER PSB10240307A BULL GEAR BEARING SPACER PR38M PSB10240310 PSB10240311 PSB10240313 PSB10240314 PSB10240315 PFH71M PSB10240321 PLW05 PN19 PN09 INT RETAINING RING 62MM WAVY SPRING WASHER SPANNER LOCK WASHER PSB10240303A SPANNER NUT BEARING SLEAVE WASHER STEP PIN COMPRESSION SPRING FLAT HD CAP SCR M5-.8 X 8 PSB10240317 INSERT PSB10240090 OIL CUP 1/8" DOUBLE END HOUSING STUD LOCK WASHER 7/16 HEX NUT 7/16-14 HEX NUT 5/8-18 REF PART # 325 326 327 328 329 330 331 332 333 334 335 336 337 339 340 341 342 343 344 345 346 347 348 349 DESCRIPTION PSB10240325 PCAP24M PSB10240327 BELT PULLEY GEAR CAP SCREW M5-.8 X 16 BULL GEAR PINION BEARING CAP PSB10240328 P6203VV-N WAVY SPRING WASHER DEEP GROOVE BALL BEARING 6203VV NSK PSB10240330 PINION GEAR 30T PSS20M PSB10240332 SET SCREW M8-1.25 X 8 PINION GEAR SHAFT PK19M PK14M PSB10240335 KEY 5 X 5 X 14 KEY 5 X 5 X 18 STRAIGHT GREASE FITTING 1/8 PT PSB10240336 GEARBOX HOUSING PCAP14M CAP SCREW M8-1.25 X 20 PSB10240339 PSB10240340 PCAP33M PRP02M PSS26M BULL GEAR SHIFT PINION HI-LOW DETENT PLATE CAP SCREW M5-.8 X 12 ROLL PIN 3 X 16 SET SCREW M5-.8 X 6 PSB10240344 PCAP16M PSB10240346 PSB10240347 PSB10240348 PSB10240349 HI-LOW PINION BLOCK CAP SCREW M4-.7 X 16 HI-LOW DETENT PLUNGER COMPRESSION SPRING HI-LOW LEVER ROUND KNOB 1/4-20 -76-

For Machines Mfg. Since 8/09

P A R T S

SB1025/SB1026 Gearbox

324 323 325 SB1024/SB1025/SB1026 307 301 302 303 304 303 305 306 308 309 311 310 312 313 For Reference Only 326 331 332 333 334 309 314 327 322 315 316 317 318 321 320 319 328 329 330 For Reference Only -77-

SB1024/SB1025/SB1026

P A R T S

For Machines Mfg. Since 8/09

SB1025/SB1026 Gearbox Parts List

REF PART # DESCRIPTION 310 311 312 313 314 315 316 317 301 302 303 304 PN04 PFH07M HEX NUT 5/8-11 FLAT HD SCR M5-.8 X 10 PSB10250303 PULLEY FLANGE PSB10250304 TIMING BELT PULLEY 305 306 PCAP33M CAP SCREW M5-.8 X 12 PSB10250306 GEARBOX COVER 307A PSB10240307A BEARING SPACER ASSEMBLY 307 308 309 PSB10240307A GREASE FITTING 1/8 PSB10240307A WAVE SPRING WASHER P6203VV-N DEEP GROOVE BALL BEARING 6203VV NSK PK20M PSB10250311 PSB10250312 PSB10250313 PSB10250314 PSB10250315 PSB10250316 PSB10250317 KEY 5 X 5 X 15 PINION GEAR SHAFT PINION GEAR 26T BACK GEAR SHIFTER FORK STEPPED PIN BACK GEAR SHIFT CRANK BACK GEAR SHIFT BUSHING SHIFT CRANK REF PART # 328 329 330 331 332 333 334 318 319 320 321 322 323 324 325 326 327 DESCRIPTION PSS02M PSB10240018 PSB10250320 PSB10250321 PSB10250322 PSB10250323 PK70M PSB10250325 PSB10250326 P6908VV-N SET SCREW M6-1 X 6 ROUND KNOB 1/4-20 COMPRESSION SPRING GEAR SHIFT PLUNGER SPECIAL HARDENED HEX NUT 1/4-20 SPLINE GEAR HUB KEY 8 X 8 X 12 SPINDLE BULL GEAR GEARBOX HOUSING DEEP GROOVE BALL BEARING 6908VV NSK PSB10250328 PSB10250329 INT RETAINING RING SPANNER LOCK WASHER PSB10250330 SPANNER NUT PCAP01M PSB10250332 PLW05 PN19 CAP SCREW M6-1 X 16 T-BOLT LOCK WASHER 7/16 HEX NUT 7/16-14 -78-

For Machines Mfg. Since 8/09

P A R T S

SB1024 Belt Housing

419 468 467 415 416 417 495 492 493 491 498 497 496 494 480 481 477 479 485 486 476 470 471 472 469 478 482 483 484 487 475 427 473 429 428 474 430 431 432 433 434 488 489 490 409 433 436 437 438 454 455 456 453 452 458 451 450 439 440 441 442 449 448 457 449 459 460 463 464 465 466 414 418 402 424 425 426 422 423 404 406 415 409 410 435 411 443 444 445 446 447 432 462 461 420 421 SB1024/SB1025/SB1026 401 402 405 407 408 407 412 413 For Reference Only 403 403A 403-1 403-2 403-3 403-4 403-5 -79-

SB1024/SB1025/SB1026

P A R T S

For Machines Mfg. Since 8/09

SB1024 Belt Housing Parts List

REF PART # DESCRIPTION 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437 438 439 440 441 442 443 444 445 446 410 411 412 413 414 415 416 417 418 419 420 421 422 401 402 PCAP14 PLW06M CAP SCREW 3/8-16 X 1 LOCK WASHER 10MM 403A PSB10240403A MOTOR ASSEMBLY 403 PSB10240403A MOTOR 2HP 220V 1PH 403-1 PSB10240403A MOTOR FAN COVER 403-2 PSB10240403A MOTOR FAN 403-3 PSB10240403A CAPACITOR COVER 403-4 PSB10240403A S CAPACITOR 600M 125V 2 X 3-1/2 403-5 PSB10240403A MOTOR JUNCTION BOX 404 PK28M KEY 7 X 7 X 30 405 406 407 408 409 PSB10240405 PSS20M UPPER MOTOR PULLEY PLATE SET SCREW M8-1.25 X 8 PSB10240407 MOTOR PULLEY PLASTIC RING PSB10240408 LOWER MOTOR PULLEY PLATE PFH31M FLAT HD SCR M4-.7 X 8 PSB10240410 PSB10240411 PSB10240412 PR20M PSS05M PCAP02M PSB10240416 P6007VV-N PN08 PSB10240419 PSB10240420 PS05M P6204VV-N MOTOR PULLEY ALIGNMENT KEY MOTOR SHAFT COMPRESSION SPRING SPRING SEAT INT RETAINING RING 28MM SET SCREW M5-.8 X 10 CAP SCREW M6-1 X 20 TOP BEARING COVER DEEP GROOVE BALL BEARING 6007VV NSK HEX NUT 3/8-16 BELT HOUSING REAR VENT COVER PHLP HD SCR M5-.8 X 8 DEEP GROOVE BALL BEARING 6204VV NSK PSB10240423 PSB10240424 PW01M PSB10240426 PCAP24M PSB10240428 PSB10240429 PR12M PSB10240431 P6010VV-N PSB10240433 PSB10240434 PSB10240435 PSB10240436 RIBBED DRIVE BELT 38-12-890 PR68M EXT RETAINING RING 40MM PSB10240438 PK27M PS68M PW03M PSB10240442 PS11M PSB10240444 PS12M PSB10240446 MOTOR PULLEY COVER SPEED CHANGE PLATE PIVOT STUD FLAT WASHER 8MM COTTER PIN 1/8 CAP SCREW M5-.8 X 16 PIVOT SLEET SPEED CHANGE PLATE EXT RETAINING RING 35MM SLIDE HOUSING DEEP GROOVE BALL BEARING 6010VV NSK SPINDLE PULLEY PLASTIC RING SPINDLE PULLEY ALIGNMENT KEY UPPER SPINDLE PULLEY PLATE LOWER SPINDLE PULLEY PLATE KEY 7 X 7 X 25 PHLP HD SCR M6-1 X 10 FLAT WASHER 6MM BRAKE BEARING CAP PHLP HD SCR M6-1 X 16 BRAKE SHOE PIVOT SLEEVE PHLP HD SCR M3-.5 X 6 BRAKE SHOE SPRING REF PART # 447 448 449 450 451 452 453 454 455 456 457 458 459 460 461 462 463 464 465 466 467 468 469 470 471 472 473 474 475 476 477 478 479 480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 495 496 497 498 DESCRIPTION PSB10240447 PR47M PSS03M PSB10240450 PSB10240451 PEC02M PSB10240453 PSS26M PSB10240455 PSB10240456 PSB10240449 PSB10240458 PSB10240459 PR36M PSB10240461 BRAKE SHOE SET EXT RETAINING RING 13MM SET SCREW M6-1 X 8 BRAKE SHAFT SLEEVE BRAKE SHAFT E-CLIP 4MM BRAKE LEVER BRACKET SET SCREW M5-.8 X 6 GROOVED PIN BRAKE LEVER ROUND KNOB 3/8-16 BRAKE OPERATING FINGER BRAKE FINGER PIVOT STUD EXT RETAINING RING 7MM BRAKE SEAT PCAP01M CAP SCREW M6-1 X 16 PSB10240463 SPINDLE PULLEY SPACER PSB10240464 PSB10240465 SPINDLE PULLEY HUB TIMING BELT 225L-100 PSB10240466 TIMING PULLEY CLUTCH SLEEVE SB1319 SOUTH BEND NAMEPLATE 90MM PS05M PRP56M PHLP HD SCR M5-.8 X 8 ROLL PIN 4 X 25 PSB10240470 PSB10240471 PSS45M PSB10240473 PSB10240474 UPPER SPEED CHANGE STUD SPEED CHANGE STUD SLEEVE SET SCREW M3-.5 X 6 LOWER SPEED CHANGE STUD SPEED CHANGE CHAIN PN04M PRP16M PSB10240477 PRP03M HEX NUT M4-.7

ROLL PIN 3 X 25 SPEED CHANGE CHAIN DRUM ROLL PIN 5 X 20 PSB10240479 BUSHING PSB10240480 SPEED CHANGE WORM GEAR PRP35M PRP61M ROLL PIN 5 X 10 ROLL PIN 3 X 12 PSB10240483 PSB10240484 WORM BRONZE SLEEVE BEARING PSB10240485 BUSHING PSB10240486 SPEED CONTROL SHAFT PSS02M SET SCREW M6-1 X 6 PSB10240488 SPEED CHANGE HANDWHEEL PSB10240489 HANDWHEEL HANDLE PSB10240490 SPEED CHANGE WARNING PLATE PSB10240491 SPEED CHANGE HOUSING PCAP48M PSS11M PSB10240494 PSB10240495 CAP SCREW M6-1 X 35 SET SCREW M6-1 X 16 BRONZE SLEEVE BEARING VARIABLE SPEED DIAL PN02 PSB10240497 PS79M HEX NUT 5/16-18 VARIABLE SPEED DIAL PLATE PHLP HD SCR M3-.5 X 8 -80-

For Machines Mfg. Since 8/09

P A R T S

SB1025/SB1026 Belt Housing

SB1024/SB1025/SB1026 -81-

SB1024/SB1025/SB1026

P A R T S

For Machines Mfg. Since 8/09

SB1025/SB1026 Belt Housing Parts List

REF PART # DESCRIPTION 408 409 410 411 412 413 414 415 416 417 418 419 401 401 PSB10250401 PSB10260401 401-1 PSB10250401-1 401-1 PSB10260401-1 MOTOR 2HP 220V 3PH (SB1025) MOTOR 2HP 220V 1PH (SB1026) MOTOR FAN COVER (SB1025) MOTOR FAN COVER (SB1026) 401-2 PSB10250401-2 MOTOR FAN (SB1025) 401-2 PSB10260401-2 MOTOR FAN (SB1026) 401-3 PSB10250401-3 MOTOR JUNCTION BOX (SB1025) 401-3 PSB10260401-3 MOTOR JUNCTION BOX (SB1026) 401-4 PSB10260401-4 CONTACTOR COVER (SB1026) 401-5 PSB10260401-5 S CAPACITOR 600M 125V (SB1026) 402 403 PN11 PSB10250403 HEX NUT 3/8-24 BELT TENSION ADJUSTMENT LEVER 404 405 406 407 PSB10250407 PSB10250405 PK28M PW01M KNOB 5/16-18 MOTOR PULLEY KEY 7 X 7 X 30 FLAT WASHER 8MM PCAP14M PS79M PSB10250410 PSB10250411 PSB10250412 PSB10250413 PN02 PSB10250415 PSB10250416 PSB10250417 PSB10250418 PSB10250419 CAP SCREW M8-1.25 X 20 PHLP HD SCR M3-.5 X 8 CAM RING COVER CAM RING CAM RING SCREW M6-1 X 8 MOTOR MOUNTING STUD 1/2-13 X 2-3/16 HEX NUT 5/16-18 BELT HOUSING MOTOR MOUNTING WASHER 21 X 13 X 3MM MOTOR LOCK NUT MOTOR LOCK LEVER KNOB 1/4-20 REF PART # 437 438 439 440 441 442 443 444 445 446 447 448 420 421 422 423 424 425 426 427 428 429 430 431 433 434 435 436 PEC13M PSB10250421 PSS26M PSB10250423 PSB10250424 SB1319 PS05M PRIV001M PSB10250428 PSB10250429 PSB10250430 PSB10250431 PSB10250433 PS12M PSB10250435 PSB10250436 P6207VV-N PSB10250438 PSB10250439 PSB10250440 PSS45M PSB10250442 PSB10250443 PVA33 PSB10250445 PK143M PSB10250447 PSB10250448 DESCRIPTION E-CLIP 5MM BRAKE HANDLE SET SCREW M5-.8 X 6 GROOVED PIN BRAKE HANDLE PIVOT RING SOUTH BEND NAMEPLATE 90MM PHLP HD SCR M5-.8 X 8 FLUTED RIVET 2 X 5MM STEEL SPINDLE SPEED PLATE BRAKE STUD BRAKE RING SCREW BRAKE SHOE SET COMPRESSION SPRING PHLP HD SCR M3-.5 X 6 INNER BEARING RETAINING RING OUTER BEARING RETAINING RING DEEP GROOVE BALL BEARING 6207VV NSK BEARING SPACER BEARING SPACER COMPRESSION SPRING SET SCREW M3-.5 X 6 BEARING SEAT SPINDLE PULLEY V-BELT A33 SPINDLE PULLEY SPLINE KEY 6 X 6 X 25 TIMING BELT 225L-100 TIMING PULLEY CLUTCH SLEEVE -82-

For Machines Mfg. Since 8/09

Ram

P A R T S

SB1024/SB1025/SB1026 -83-

SB1024/SB1025/SB1026

Ram Parts List

REF PART # 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 DESCRIPTION PCAP31M PRP90M PSB10240503 PRIV001M PSB10240505 CAP SCREW M8-1.25 X 25 ROLL PIN 8 X 30 GEAR 33T FLUTED RIVET 2 X 5MM STEEL HEAD ROTATION SCALE PSB10240506 RAM ADAPTER PSB10240507 INDICATOR PLATE PSB10240508 WORM THRUST WASHER PSB10240509 LOCK COLLAR PSS02M SET SCREW M6-1 X 6 PK36M KEY 5 X 5 X 50 PSB10240512 PSB10240513 PSB10240514 PW10M PR19M HEAD TILT WORM HEAD TILT SCALE TILT LOCK BOLT FLAT WASHER 14MM EXT RETAINING RING 28MM

P A R T S

For Machines Mfg. Since 8/09 REF PART # DESCRIPTION 517 518 519 520 521 522 523 524 525 526 527 PSB10240517 PSB10240518 PSB10240519 PSB10240520 PSB10240521 PSB10240522 PSB10240523 PSB10240524 PSB10240525 PSB10240526 PN08 TILT PIVOT STUD TILT LOCK BOLT BUSHING HEAD TILT WORM SHAFT LIFTING EYE BOLT 3/4-10 RAM RAM GIB TURRET CLAMP BOLT RAM PINION SCREW TURRET RAM GIB ADJUSTMENT SCREW HEX NUT 3/8-16 528 PSB10240528 RAM LOCK PLUNGER 530A PSB10240530A LOCK LEVER ASSEMBLY 533 PSB10240533 RAM PINION 534 535 PSB10240534 PSB10240535 RAM ROTATION SCALE TURRET BRACKET -84-

For Machines Mfg. Since 8/09

P A R T S

Column, Knee, & Saddle

SB1024/SB1025/SB1026 626A* Av 648 649 -85-

SB1024/SB1025/SB1026

P A R T S

For Machines Mfg. Since 8/09

Column, Knee, & Saddle Parts List

REF PART # DESCRIPTION

601 602 603 604 605 606 PSB10240601 COLUMN PRIV001M FLUTED RIVET 2 X 5MM STEEL PSB10240603 INDICATOR PLATE PSB10240604 REAR COLUMN COVER PS09M PHLP HD SCR M5-.8 X 10 PSB10240606 PIPE PLUG 1/2 PT 607 608 609 610 PS40M PW02M PCAP11M PLW04M PHLP HD SCR M5-.8 X 16 FLAT WASHER 5MM CAP SCREW M8-1.25 X 16 LOCK WASHER 8MM 613A PSB10240613A KNEE LOCK LEVER ASSEMBLY 615 PSB10240615 UPPER KNEE LOCK PLUNGER 616 PSB10240616 LOWER KNEE LOCK PLUNGER 617 618 P51305 PK20M THRUST BEARING 51305 KEY 5 X 5 X 15 629 630 631 632 633 634 635 636 619A PSB10240619A VERTCAL LEADSCREW W/NUT ASSY 619 PSB10240619A VERTICAL LEADSCREW INCH 620 PCAP02M CAP SCREW M6-1 X 20 621 622 PSB10240619A VERTICAL LEADSCREW BEVEL NUT INCH PZERK005 GREASE FITTING ST 1/8 PT 623 624 625 PSB10240623 VERTICAL LEADSCREW HOUSING PCAP19 CAP SCREW 3/8-16 X 1-1/4 PSB10240625 COOLANT SCREEN 626A PSB10240626A KNEE/SADDLE WIPER ASSEMBLY 626 PSB10240626A RIGHT KNEE WIPER 627 628 PSB10240626A LEFT KNEE WIPER PSB10240628 GIB SCREW PSB10240629 KNEE GIB PN01 HEX NUT 1/2-20 PSB10240631 BEVEL GEAR FLAT WASHER 1/2 PSB10240632 BEVEL GEAR P6205ZZ BALL BEARING 6205ZZ PSB10240634 KNEE PSB10240635 CRANK HANDLE PSB10240636 VERTICAL CRANK

REF PART # DESCRIPTION

637 638 639 640 641 642 PSB10240637 CRANK CLUTCH PSB10240638 FRONT DIAL RETAINER PSB10240639 VERTICAL DIAL INCH PSB10240640 REAR DIAL RETAINER PCAP01M CAP SCREW M6-1 X 16 PSB10240642 BEARING RETAINER 643 644 645 646 P6204ZZ BALL BEARING 6204ZZ PSB10240644 BEARING SEAT PK47M KEY 4 X 4 X 15 PSB10240646 VERTICAL CRANK SHAFT 647 648 649 PK48M PSS02M KEY 4 X 4 X 20 SET SCREW M6-1 X 6 PSB10240649 BEVEL PINION 650 PSS03M SET SCREW M6-1 X 8 651A PSB10240651A CHIP GUARD SET 651 652 653 654 655 656 657 658 659 660 661 662 663 664 665 PSB10240651A OUTER CHIP GUARD PSB10240651A MIDDLE CHIP GUARD PSB10240651A INNER CHIP GUARD PSB10240654 WAY COVER SUPPORT PN06M PSB10240626A FRONT SADDLE WIPER PSB10240657 PSB10240658 LEFT TABLE LOCK PLUNGER PSB10240659 RIGHT TABLE LOCK PLUNGER PSB10240660 SADDLE LOCK PLUNGER PSB10240661 HEX NUT M5-.8

SADDLE GIB TABLE GIB SCREW PSB10240662 TABLE GIB PSB10240663 SADDLE PSB10240626A REAR SADDLE WIPER PCAP01M CAP SCREW M6-1 X 16 666 667 PSB10240666 FRONT WAY COVER PSB10240667 LAMP MOUNTING BRACKET 667-1 PSB10240667-1 REAR WAY COVER 668 PSB10240668 HALOGEN WORK LAMP ASSY 24V -86-

For Machines Mfg. Since 8/09

Table

P A R T S

SB1024/SB1025/SB1026 714A‡ Av 732A* Av -87-

SB1024/SB1025/SB1026

P A R T S

Table Parts List

REF PART # DESCRIPTION 715 716 717 718 719 720 721 722 701 702 703 704A PSB10240704A DIAL HOLDER ASSEMBLY 704 PSB10240704A OUTER DIAL HOLDER 705 PSB10240705 TABLE DIAL INCH 706 707 PN01 PSB10240702 PSB10240703 HEX NUT 1/2-20 HANDLE CROSS FEED BALL HANDLE PSB10240704A INNER DIAL HOLDER PCAP01M CAP SCREW M6-1 X 16 708 709 710 711 712 713 PSB10240708 P6204ZZ PRP05M PCAP14 PSB10240712 PK92M BEARING RETAINER RING BALL BEARING 6204ZZ ROLL PIN 5 X 30 CAP SCREW 3/8-16 X 1 CROSS FEED BEARING BRACKET KEY 3 X 3 X 25 714A PSB10240714A CROSS FEED LEADSCREW W/NUTS ASSY 714 PSB10240714A CROSS FEED LEADSCREW PSS01 PW07 PSB10240717 PSB10240718 PSB10240719 PSB10240720 PSB10240721 PR39M SET SCREW 5/16-18 X 1 FLAT WASHER 5/16 TRAVEL STOP TRAVEL STOP SHAFT COMPRESSION SPRING TRAVEL STOP T-NUT TRAVEL STOP FLAT WASHER 8MM EXT RETAINING RING 8MM For Machines Mfg. Since 8/09 REF PART # DESCRIPTION 741 742 743 744 745 746 747 748 733 734 735 736 737 738 739 740 723A PSB10240723A LONGITUDINAL BALL HANDLE ASSY 723 PSB10240723A LONGITUDINAL BALL HANDLE 724 PSS08M SET SCREW M4-.7 X 5 725 729 730 731 732 PSB10240723A TABLE BALL HANDLE CLUTCH ASSY PSB10240729 PSB10240730 PSB10240732 TABLE BEARING BRACKET RUBBER TABLE T-SLOT PLUG PSB10240606 PIPE PLUG 1/2 PT LONGITUDINAL LEADSCREW INCH PCAP06M PW03M PSB10240736 PSB10240737 PSB10240739 PSB10240740 CAP SCREW M6-1 X 25 FLAT WASHER 6MM PSB10240714A FRONT CROSS LEADSCREW NUT LEADSCREW NUT BRACKET LEFT LONGITUDINAL LEADSCREW NUT PSB10240714A REAR CROSS FEED LEADSCREW NUT RIGHT LONGITUDINAL LEADSCREW NUT BEARING RETAINING RING PSB10240741 PSB10240742 PSB10240743 PSB10240744 PSB10240745 PSB10240746 PW02 PCAP100 POWER FEED ASSEMBLY BEVEL GEAR BUSHING POWER FEED BEVEL GEAR BEVEL GEAR NUT TABLE 9 X 42" LONGITUDINAL LIMIT SWITCH ASSEMBLY FLAT WASHER 3/8 CAP SCREW 3/8-16 X 1/2 -88-

For Machines Mfg. Since 8/09

One-Shot Oiler

801 802 803 804

K

805 808 807 806

P A R T S

SB1024/SB1025/SB1026 801

F C B G E A D H

REF PART # 801 802 803 804 DESCRIPTION PSB10240801 PCAP02M ELBOW JOINT M4 X 1/8 PT PSB10240802 T-JOINT PSB10240803 ONE SHOT OILER ASSEMBLY CAP SCREW M6-1 X 20 Oil distributor

A B C D E F G H

REF PART # 805 806 807 808 DESCRIPTION PCAP01M CAP SCREW M6-1 X 16 PSB10240806 FLEXIBLE STEEL TUBE 4 X 500MM PCAP38M CAP SCREW M5-.8 X 25 PSB10240808 OIL DISTRIBUTOR 8-PORT 801

K

-89-

SB1024/SB1025/SB1026

P A R T S

SB1024/SB1026 Electrical Box & Control Panel

Electrical Box

901 902 903 904 For Machines Mfg. Since 8/09 905 905 906 917 907

Control Panel

913 914 912 919 915 916 918 908 911 910 REF PART # 901 902 903 904 905 906 907 908 910 DESCRIPTION PSB10240901 PSB10240902 TRANSFORMER 24-440V YJ A009-0383 FUSE HOLDER 30A PSB10240903 FUSE 30A PSB10240904 FUSE HOLDER 2-5A PSB10240905 FUSE 5A PSB10240906 FUSE 2A PSB10240907 CONTACTOR AB C09-400 220V PSB10240908 TERMINAL BAR 6-POST PSB10240910 POWER RECEPTACLE 100V REF PART # 911 912 913 914 915 916 917 918 919 PSB10240911 PSB10240912 PSB10240913 PSB10240914 PSB10240915 PSB10240916 PSB10240917 PSB10240918 PSB10240919 DESCRIPTION CONTROL PANEL POWER INDICATOR ASSEMBLY SPINDLE START BUTTON ASSEMBLY SPINDLE DIRECTION SWITCH ASSEMBLY EMERGENCY STOP BUTTON ASSEMBLY SPINDLE STOP BUTTON ASSEMBLY CONTACTOR AB C16-01 220V TERMINAL BAR 12-POST RELAY OMERON MY2J 24V -90-

For Machines Mfg. Since 8/09

P A R T S

SB1024/SB1025/SB1026

SB1025 Electrical Box & Control Panel

Electrical Box

901 902 904 905 907 903 905 906 908

Control Panel

913 912 916 915 914 909 911 910 REF PART # 901 902 903 904 905 906 907 908 DESCRIPTION PSB10240901 PSB10240902 TRANSFORMER 24-440V YJ A009-0383 FUSE HOLDER 30A PSB10240903 FUSE 30A PSB10240904 FUSE HOLDER 2-5A PSB10240905 FUSE 5A PSB10240906 FUSE 2A PSB10240907 CONTACTOR AB C09-400 220V PSB10240908 TERMINAL BAR 6-POST REF PART # 909 910 911 912 913 914 915 916 DESCRIPTION PSB10250909 TERMINAL BAR 17-POST PSB10240910 POWER RECEPTACLE 100V PSB10250911 PSB10240912 PSB10240913 CONTROL PANEL POWER INDICATOR ASSEMBLY SPINDLE START BUTTON ASSEMBLY PSB10250914 PSB10240915 PSB10240916 SPINDLE DIRECTION SWITCH ASSEMBLY EMERGENCY STOP BUTTON ASSEMBLY SPINDLE STOP BUTTON ASSEMBLY -91-

SB1024/SB1025/SB1026

Accessories

1001 1002

P A R T S

1003 For Machines Mfg. Since 8/09 1004 1007 1006 REF PART # 1001 PWR1921C 1002 PWR1214 1003 PAW1510M 1004 PSB10241004 DESCRIPTION CLOSED END WRENCH 19/21MM WRENCH 12/14MM HEX WRENCH SET 10PC 1.5-10 MM TOOL BOX 1005 REF PART # 1005 PSDF2 1006 PSDP2 1007 PSB10241007 DESCRIPTION FLAT SCREWDRIVER #2 PHILLIPS SCREWDRIVER #2 OIL BOTTLE -92-

For Machines Mfg. Since 8/09

P A R T S

SB1024 Head Machine Labels

SB1024/SB1025/SB1026 1106 1102 1101 1104 1103 1105 REF PART # 1101 1102 1103 DESCRIPTION PSB10241101 MACHINE ID LABEL PSBLABEL07VL EYE INJURY HAZARD LABEL PSBLABEL01VL READ MANUAL LABEL REF PART # 1104 1105 1106 PSB10241104 PSB10241105 PSB10241106 DESCRIPTION SPEED RANGE LABEL DOWNFEED WARNING LABEL VARIABLE SPINDLE SPEED LABEL

The safety labels provided with your machine are used to make the operator aware of the machine hazards and ways to prevent injury. The owner of this machine MUST maintain the original location and readability of these safety labels. If any label is removed or becomes unreadable, REPLACE that label before using the machine again. Contact South Bend Lathe Co. at (360) 734-1540 or www.southbendlathe.com to order new labels.

-93-

SB1024/SB1025/SB1026

P A R T S

SB1024 Main Machine Labels

For Machines Mfg. Since 8/09 1108 1107 1123 1122 1109 1110 1111 1124 1113 1114 1112 1115 1120 1116 1117 1126 1125 1121 1118 1119 REF PART # 1107 1108 1109 1110 1111 1112 1113 1114 1115 1116 DESCRIPTION PSBLABEL08VL ENTANGLEMENT HAZARD LABEL SB1319 SOUTH BEND NAMEPLATE 90MM PSB10241109 PSB10241110 PSB10241111 SPINDLE SPEED DISPLAY LABEL HEAD LUBRICATION LABEL MODEL NUMBER LABEL PSB10241112 PSB10241113 PSB10241114 PSB10241115 PSB10241116 POWER FEED WARNING LABEL POWER FEED RAPID FEED LABEL POWER FEED CONTROL LABEL POWER FEED NOTICE LABEL 110V 1PH LABEL -94 REF PART # 1117 1118 1119 1120 1121 1122 1123 1124 1125 1126 DESCRIPTION PSB10241117 PSB10241118 PSB10241119 PSB10241120 PSB10241121 220V 1PH LABEL 110V 1PH 5.5A LABEL PLUG RECEPTACLE FIRE HAZARD LABEL ELECTRICAL BOX WARNING LABEL CONTROL PANEL LABEL PSBLABEL02VL DISCONNECT POWER LABEL PSB10241123 QUALIFIED PERSONNEL NOTICE LABEL PSBPAINT01 SB GRAY TOUCH-UP PAINT PSBPAINT02 PSBPAINT03 SB LIGHT BLUE TOUCH-UP PAINT SB DARK BLUE TOUCH-UP PAINT

For Machines Mfg. Since 8/09

P A R T S

SB1025/SB1026 Machine Labels

SB1024/SB1025/SB1026 1108 1107 1127 1105 1101 1111 1102 1123 1122 1103 1113 1115 1121 1114 1112 1124 1126 1125 1128 1120 1118 1119 REF PART # 1101 1101 1102 1103 1105 1107 1108 1111 1111 1112 1113 1114 DESCRIPTION PSB10251101 PSB10261101 MACHINE ID LABEL (SB1025) MACHINE ID LABEL (SB1026) PSBLABEL07VL EYE INJURY HAZARD LABEL PSBLABEL01VL READ MANUAL LABEL PSB10241105 DOWNFEED WARNING LABEL PSBLABEL08VL ENTANGLEMENT HAZARD LABEL SB1319 SOUTH BEND NAMEPLATE 90MM PSB10251111 MODEL NUMBER LABEL (SB1025) PSB10261111 PSB10241112 PSB10241113 PSB10241114 MODEL NUMBER LABEL (SB1026) POWER FEED WARNING LABEL POWER FEED RAPID FEED LABEL POWER FEED CONTROL LABEL REF PART # 1115 1118 1119 1120 1121 1122 1123 1124 1125 1126 1127 1128 DESCRIPTION PSB10241115 PSB10241118 PSB10241119 PSB10241120 PSB10241121 POWER FEED NOTICE LABEL 110V 1PH 5.5A LABEL PLUG RECEPTACLE FIRE HAZARD LABEL ELECTRICAL BOX WARNING LABEL CONTROL PANEL LABEL PSBLABEL02VL DISCONNECT POWER LABEL PSB10241123 QUALIFIED PERSONNEL NOTICE LABEL PSBPAINT01 SB GRAY TOUCH-UP PAINT PSBPAINT02 PSBPAINT03 PSB10251127 PSB10251128 SB LIGHT BLUE TOUCH-UP PAINT SB DARK BLUE TOUCH-UP PAINT SPINDLE SPEED CHART LABEL 220V 3PH LABEL -95-

W A R R A N T Y

This quality product is warranted by South Bend Lathe Company to the original buyer for one year from the date of purchase. This warranty does not apply to consumable parts, or defects due to any kind of misuse, abuse, negligence, accidents, repairs, alterations or lack of maintenance. We do not reimburse for third party repairs. In no event shall we be liable for death, injuries to persons or property, or for incidental, contingent, special or consequential damages arising from the use of our products.

We do not warrant or represent that this machine complies with the provisions of any law, act, code, regulation, or standard of any domestic or foreign government, industry, or authority. In no event shall South Bend’s liability under this warranty exceed the original purchase price paid for this machine. Any legal actions brought against South Bend Lathe Company shall be tried in the State of Washington, County of Whatcom.

This is the sole written warranty for this machine. Any and all warranties that may be implied by law, including any merchantability or fitness, for any purpose, are hereby limited to the duration of this warranty. To take advantage of this warranty, contact us by mail or phone to give us the details of the problem you are having.

Thank you for your business and continued support.

Printed In Taiwan #JBTS12116

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