MODEL M1001 6" X 26" VERTICAL MILL INSTRUCTION MANUAL Phone: (360) 734-3482 • On-Line Technical Support: tech-support@shopfox.biz COPYRIGHT © JANUARY, 2005 BY WOODSTOCK INTERNATIONAL, INC., REVISED JANUARY, 2015 (ST) #6799PC WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC. Printed in China This manual provides critical safety instructions on the proper setup, operation, maintenance, and service of this machine/tool. Save this document, refer to it often, and use it to instruct other operators. Failure to read, understand and follow the instructions in this manual may result in fire or serious personal injury—including amputation, electrocution, or death. The owner of this machine/tool is solely responsible for its safe use. This responsibility includes but is not limited to proper installation in a safe environment, personnel training and usage authorization, proper inspection and maintenance, manual availability and comprehension, application of safety devices, cutting/sanding/grinding tool integrity, and the usage of personal protective equipment. The manufacturer will not be held liable for injury or property damage from negligence, improper training, machine modifications or misuse. Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are: • Lead from lead-based paints. • Crystalline silica from bricks, cement and other masonry products. • Arsenic and chromium from chemically-treated lumber. Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: Work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles. SAFETY................................................7 Standard Machinery Safety Instructions....... 7 Additional Safety Instructions for Vertical Mills................................................. 9 WARRANTY......................................... 40 Warranty Registration.......................... 41 OPERATIONS MAINTENANCE OPERATIONS....................................... 18 General........................................... 18 Positioning Spindle Head....................... 18 Table Travel...................................... 19 Graduated Dials................................. 20 Power Feed Controls............................ 20 Quill Travel....................................... 21 Determining Needed RPM...................... 22 Setting RPM...................................... 23 Spindle Break-in Procedure.................... 24 Installing Tools................................... 25 Removing Cutting Tools........................ 25 PARTS............................................... 35 Headstock Assembly............................ 35 Base Assembly................................... 36 Machine Parts Lists.............................. 37 Machine Labels.................................. 39 SET UP SETUP............................................... 13 Unpacking........................................ 13 Inventory......................................... 13 Machine Placement............................. 14 Cleaning Machine................................ 14 Mounting Mill on Shop Floor................... 15 Assembly.......................................... 16 Headstock Adjustment......................... 16 Handle Installation.............................. 16 Drawbar........................................... 16 Single Shot Lubrication......................... 16 Spindle Controls................................. 17 Test Run........................................... 17 SERVICE............................................. 29 General........................................... 29 Gibs................................................ 29 Adjusting Backlash.............................. 30 Electrical Safety Instructions.................. 31 Electrical Parts Identification................. 32 Wiring Diagram.................................. 33 Troubleshooting.................................. 34 Headstock Assembly............................ 35 ELECTRICAL ELECTRICAL........................................ 10 MAINTENANCE..................................... 26 General........................................... 26 Cleaning.......................................... 26 Table and Base................................... 26 Lubrication....................................... 27 Maintenance Schedule.......................... 28 Maintenance Notes.............................. 28 SAFETY INTRODUCTION......................................2 Woodstock Technical Support................... 2 About Your New 6" x 26" Vertical Mill.......... 2 Machine Specifications........................... 3 INTRODUCTION Table of Contents SERVICE PARTS USE THE QUICK GUIDE PAGE LABELS TO SEARCH OUT INFORMATION FAST! INTRODUCTION M1001 6" x 26" Vertical Mill INTRODUCTION Woodstock Technical Support We stand behind our machines! In the event that questions arise about your machine, parts are missing, or a defect is found, please contact Woodstock International Technical Support at (360) 734-3482 or send e-mail to: tech-support@shopfox.biz. Our knowledgeable staff will help you troubleshoot problems and send out parts for warranty claims. If you need the latest edition of this manual, you can download it from http://www.shopfox.biz. If you still have questions after reading the latest manual, or if you have comments please contact us at: Woodstock International, Inc. Attn: Technical Support Department P.O. Box 2309 Bellingham, WA 98227 About Your New 6" x 26" Vertical Mill Your new SHOP FOX® 6" x 26" Vertical Mill has been specially designed to provide many years of troublefree service. Close attention to detail, ruggedly built parts and a rigid quality control program assure safe and reliable operation. Woodstock International, Inc. is committed to customer satisfaction in providing this manual. It is our intent to make sure all the information necessary for safety, ease of assembly, practical use and durability of this product be included. -2- INTRODUCTION M1001 6" x 26" Vertical Mill MODEL M1001 SHOP FOX® VERTICAL MILL 6" X 26" Motors Main Type......................................................................... TEFC Capacitor Start Induction Horsepower........................................................................................... 1-1/2 HP Voltage.............................................................................................. 110V/220V Prewired.................................................................................................... 110V Phase.............................................................................................. Single-Phase Amps................................................................................. 16A at 110V, 8A at 220V Speed.................................................................................................. 1725 RPM Cycle....................................................................................................... 60 Hz Number of Speeds............................................................................................. 1 Power Transfer ................................................................................... V-Belt Drive Bearings................................................................. Shielded, Permanently Lubricated Main Specifications Operation Info Spindle Travel.............................................................................................. 3 in. Swing....................................................................................................... 11 in. Longitudinal Table Travel......................................................................... 14-1/4 in. Cross Table Travel......................................................................................... 6 in. Vertical Table Travel.................................................................................... 14 in. Knee Travel........................................................................................... 11-3/4 in Ram Travel................................................................................................ 12 in. Head Travel........................................................................................... 2-1/2 in. Head Swivel (Left-to-Right).......................................................................... 90 deg. Head Swivel (Front-to-Back)......................................................................... 45 deg. Turret or Column Swivel (Left and Right)........................................................ 360 deg. Maximum Distance Spindle to Column............................................................ 5-1/2 in. Maximum Distance Spindle to Table............................................................. 11-7/8 in. Drilling Capacity for Cast Iron........................................................................... 1 in. Drilling Capacity for Steel............................................................................. 3/4 in. Number of Vertical Spindle Speeds......................................................................... 9 Range of Vertical Spindle Speeds........... 240, 360, 520, 730, 1280, 1320, 1600, 2220, 2760 RPM Number of Longitudinal Feeds...................................................................... Variable Feed Rate......................................................................................... 0 — 140 FPM Quill Diameter........................................................................................ 2.950 in. Model M1001 Machine Specifications, Page 1 of 3 -3- INTRODUCTION M1001 6" x 26" Vertical Mill Table Info Table Length.............................................................................................. 26 in. Table Width........................................................................................... 6-1/8 in. Table Thickness....................................................................................... 1-3/4 in. Number of T-Slots............................................................................................. 3 T-Slots Width.......................................................................................... 0.560 in. T-Slots Height......................................................................................... 0.850 in. T-Slots Centers...................................................................................... 1-9/16 in. Stud Size................................................................................................. 3/8 in. Spindle Info Spindle Taper................................................................................................ R-8 End Milling Capacity.................................................................................... 3/4 in. Face Milling Capacity..................................................................................... 3 in. Drawbar Diameter..................................................................................... 7/16 in. Drawbar TPI................................................................................................... 20 Drawbar Length..................................................................................... 12-1/4 in. Spindle Bearings............................................................................... Tapered Roller Lead Screw Info Leadscrew Diameter................................................................................. 15/16 in. Leadscrew TPI.................................................................................................. 8 Leadscrew Length........................................................................................ 31 in. Construction Spindle Housing/Quill................................................................................ Cast Iron Table............................................................................... Surface-Ground Cast Iron Head.................................................................................................... Cast Iron Column................................................................................................. Cast Iron Base.................................................................................................... Cast Iron Stand........................................................................................................ Steel Paint....................................................................................................... Epoxy Other Collar Graduations................................................................................... 0.001 in. Recommended Mobile Base........................................................................... D2058A Product Dimensions Weight.......................................................................................................... 900 lbs. Width (side-to-side) x Depth (front-to-back) x Height.............................. 45-1/2 x 41 x 66-5/8 in. Footprint (Length x Width)......................................................................... 27-1/2 x 21 in. Shipping Dimensions Type....................................................................................................... Wood Crate Content........................................................................................................ Machine Weight.......................................................................................................... 936 lbs. Length x Width x Height........................................................................... 37 x 41 x 75 in. Model M1001 Machine Specifications, Page 2 of 3 -4- Electrical Power Requirement............................................................. 110V/220V, Single-Phase, 60 Hz Prewired Voltage................................................................................................. 110V Minimum Circuit Size................................................................... 20A at 110V, 15A at 220V Switch................................................................................................. ON/OFF Switch Switch Voltage.................................................................................................... 110V Cord Length....................................................................................................... 6 ft. Cord Gauge.................................................................................................. 14 Gauge Plug Included....................................................................................................... Yes Included Plug Type........................................................................................ NEMA 5-15 Other Country Of Origin ............................................................................................... China Warranty ....................................................................................................... 2 Years Assembly Time ................................................................................................. 1 Hour Features Milling Head Micro-Feed Built-In Work Light Class 7 Spindle Bearings Head Tilts to 45 Deg. Both Ways. Single-Shot Lubrication System High-Precision Ground Vertical and Cross Ways Accessories Drawbar Tool Box 3 In. Shell Mill with Arbor Hex Wrench Set, 3-6mm Open End Wrenches Screwdrivers Model M1001 Machine Specifications, Page 3 of 3 -5- INTRODUCTION M1001 6" x 26" Vertical Mill INTRODUCTION M1001 6" x 26" Vertical Mill Controls and Features E D F C G B A N H O M I L J K A. Longitudinal Handwheel B.Worklight C. 3" Shell Mill D. Quill Micro-Feed Handwheel E. Quill Down Feed Lever F. Quill Lock G. Power Feed Stops H. Longitudinal Power Feed I. ON/OFF Buttons J. Cross Feed Handwheel K. Storage Compartment L. Coolant Catch Basin M. Knee Lever N. Power Feed Limit Switch O. Single Shot Lubrication System -6- M1001 6" x 26" Vertical Mill SAFETY The purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series of symbols and signal words intended to convey the level of importance of the safety messages. The progression of symbols is described below. Remember that safety messages by themselves do not eliminate danger and are not a substitute for proper accident prevention measures—this responsibility is ultimately up to the operator! Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury. NOTICE This symbol is used to alert the user to useful information about proper operation of the equipment, and/or a situation that may cause damage to the machinery. Standard Machinery Safety Instructions OWNER’S MANUAL. Read and understand this owner’s manual BEFORE using machine. Untrained users can be seriously hurt. HEARING PROTECTION. Always wear hearing protection when operating or observing loud machinery. Extended exposure to this noise without hearing protection can cause permanent hearing loss. EYE PROTECTION. Always wear ANSI-approved safety glasses or a face shield when operating or observing machinery to reduce the risk of eye injury or blindness from flying particles. Everyday eyeglasses are not approved safety glasses. MENTAL ALERTNESS. Be mentally alert when running machinery. Never operate under the influence of drugs or alcohol, when tired, or when distracted. HAZARDOUS DUST. Dust created while using machinery may cause cancer, birth defects, or long-term respiratory damage. Be aware of dust hazards associated with workpiece materials, and always wear a NIOSH-approved respirator to reduce your risk. DISCONNECTING POWER SUPPLY. Always disconnect machine from power supply before servicing, adjusting, or changing cutting tools (bits, blades, cutters, etc.). Make sure switch is in OFF position before reconnecting to avoid an unexpected or unintentional start. WEARING PROPER APPAREL. Do not wear clothing, apparel, or jewelry that can become entangled in moving parts. Always tie back or cover long hair. Wear non-slip footwear to avoid accidental slips which could cause a loss of workpiece control. DANGEROUS ENVIRONMENTS. Do not use machinery in wet or rainy locations, cluttered areas, around flammables, or in poorly-lit areas. Keep work area clean, dry, and welllighted to minimize risk of injury. -7- SAFETY For Your Own Safety, Read Manual Before Operating Machine SAFETY M1001 6" x 26" Vertical Mill APPROVED OPERATION. Untrained operators can be seriously hurt by machinery. Only allow trained or properly supervised people to use machine. When machine is not being used, disconnect power, remove switch keys, or lock-out machine to prevent unauthorized use—especially around children. Make workshop kid proof! STABLE MACHINE. Unexpected movement during operations greatly increases the risk of injury and loss of control. Verify machines are stable/secure and mobile bases (if used) are locked before starting. FORCING MACHINERY. Do not force machine. It will do the job safer and better at the rate for which it was designed. ONLY USE AS INTENDED. Only use machine for its intended purpose. Never modify or alter machine for a purpose not intended by the manufacturer or serious injury may result! AWKWARD POSITIONS. Keep proper footing and balance at all times when operating machine. Do not overreach! Avoid awkward hand positions that make workpiece control difficult or increase the risk of accidental injury. USE RECOMMENDED ACCESSORIES. Consult this owner’s manual or the manufacturer for recommended accessories. Using improper accessories will increase the risk of serious injury. UNATTENDED OPERATION. Never leave machine running while unattended. Turn machine off and ensure all moving parts completely stop before walking away. CHILDREN & BYSTANDERS. Keep children and bystanders a safe distance away from work area. Stop using machine if children or bystanders become a distraction. MAINTAIN WITH CARE. Follow all maintenance instructions and lubrication schedules to keep machine in good working condition. An improperly maintained machine may increase the risk of serious injury. REMOVE ADJUSTING TOOLS. Never leave adjustment tools, chuck keys, wrenches, etc. in or on machine—especially near moving parts. Verify removal before starting! CHECK DAMAGED PARTS. Regularly inspect machine for damaged parts, loose bolts, mis-adjusted or mis-aligned parts, binding, or any other conditions that may affect safe operation. Always repair or replace damaged parts, wires, cords, or plugs before operating machine. SECURING WORKPIECE. When required, use clamps or vises to secure workpiece. A secured workpiece protects hands and frees both of them to operate the machine. MAINTAIN POWER CORDS. When disconnecting cord-connected machines from power, grab and pull the plug—NOT the cord. Pulling the cord may damage the wires inside. Do not handle the cord/plug with wet hands. Avoid cord damage by keeping it away from heated surfaces, high traffic areas, harsh chemicals, and wet or damp locations. FEED DIRECTION. Unless otherwise noted, feed work against the rotation of blades or cutters. Feeding in the same direction of rotation may pull your hand into the cut. GUARDS & COVERS. Guards and covers can protect you from accidental contact with moving parts or flying debris. Make sure they are properly installed, undamaged, and working correctly before using machine. EXPERIENCING DIFFICULTIES. If at any time you are experiencing difficulties performing the intended operation, stop using the machine! Contact our Technical Support for help at (360) 734-3482. NEVER STAND ON MACHINE. Serious injury or accidental contact with cutting tool may occur if machine is tipped. Machine may be damaged. -8- M1001 6" x 26" Vertical Mill Additional Safety Instructions for Vertical Mills USE this and other machinery with caution and respect. Always consider safety first, as it applies to your individual working conditions. No list of safety guidelines can be complete—every shop environment is different. Failure to follow guidelines could result in serious personal injury, damage to equipment or poor work results. MILL ASSEMBLY. Do not operate until unit is assembled and installed according to instructions. UNDERSTANDING CONTROLS. Make sure you understand the use and operation of all controls. SECURING WORKPIECE. Never hold a workpiece by hand for any type of machining operation. Hold your workpiece secure with a mill vise, step clamps, etc. SECURING CUTTING TOOLS. Make sure that the cutting tool is chucked or colleted properly. Cutting tools that are loose or not rotating correctly can come off and cause serious personal injury. CUTTING TOOL INSPECTION. Inspect drills and end mills for sharpness, chips, or cracks before each use. Replace dull, chipped, or cracked cutting tools immediately. Handle new cutting tools with care. Leading edges are very sharp and can cause lacerations. USING GUARDS. Make sure cover is closed and latched before turning the machine ON. CHUCK KEY SAFETY. Always remove your chuck key, draw bar wrench, and any service tools immediately after use. CLEARING CHIPS. Turn off machine and wait for cutting tool to come to a complete stop before clearing away chips. Chips are sharp. Use a brush to remove them. FEED AND SPEED RATES. Research the proper feed and speed rate for the material you are machining. Do not exceed these recommended rates. CHANGING SPINDLE DIRECTION. Never reverse motor direction while the spindle is in motion. TURNING OFF THE MILL. Allow the mill to come to a complete stop before leaving it unattended. SERVICING THE MILL. Make sure mill is turned OFF, unplugged, and the machine has come to a complete stop before servicing. Perform routine inspections and correct service related issues promptly. HAZARDOUS COOLANTS. Coolants used for machining may contain hazardous chemicals. Read and understand all user information on the coolant container and take any necessary precautions. -9- SAFETY READ and understand this entire instruction manual before using this machine. Serious personal injury may occur if safety and operational information is not understood and followed. DO NOT risk your safety by not reading! M1001 6" x 26" Vertical Mill ELECTRICAL ELECTRICAL Availability Before installing the machine, consider the availability and proximity of the required power supply circuit. If an existing circuit does not meet the requirements for this machine, a new circuit must be installed. To minimize the risk of electrocution, fire, or equipment damage, installation work and electrical wiring must be done by a qualified electrician in accordance with all applicable codes and standards. Full-Load Current Rating The full-load current rating is the amperage a machine draws at 100% of the rated output power. On machines with multiple motors, this is the amperage drawn by the largest motor or sum of all motors and electrical devices that might operate at one time during normal operations. Full-Load Current Rating at 110V................. 16 Amps Full-Load Current Rating at 220V...................8 Amps The full-load current is not the maximum amount of amps that the machine will draw. If the machine is overloaded, it will draw additional amps beyond the full-load rating. If the machine is overloaded for a sufficient length of time, damage, overheating, or fire may result—especially if connected to an undersized circuit. To reduce the risk of these hazards, avoid overlovading the machine during operation and make sure it is connected to a power supply circuit that meets the requirements in the following section. -10- Electrocution, fire, or equipment damage may occur if machine is not correctly grounded and connected to the power supply. For your own safety and protection of property, consult a qualified electrician if you are unsure about wiring practices or electrical codes in your area. M1001 6" x 26" Vertical Mill Circuit Information A power supply circuit includes all electrical equipment between the breaker box or fuse panel in the building and the machine. The power supply circuit used for this machine must be sized to safely handle the fullload current drawn from the machine for an extended period of time. (If this machine is connected to a circuit protected by fuses, use a time delay fuse marked D.) Note: The circuit requirements listed in this manual apply to a dedicated circuit—where only one machine will be running at a time. If this machine will be connected to a shared circuit where multiple machines will be running at the same time, consult a qualified electrician to ensure that the circuit is properly sized for safe operation. Circuit Requirements for 110V Nominal Voltage.................................... 110V/120V Cycle.........................................................60 Hz Phase............................................... Single-Phase Minimum Circuit Size................................ 20 Amps Plug/Receptacle.................................... NEMA 5-15 Circuit Requirements for 220V This machine can be converted to operate on a 220V power supply (refer to Voltage Conversion later in this section). The intended 220V circuit must have a verified ground and meet the following requirements: Nominal Voltage.................................... 220V/240V Cycle.........................................................60 Hz Phase............................................... Single-Phase Minimum Circuit Size................................ 15 Amps Plug/Receptacle.................................... NEMA 6-15 -11- ELECTRICAL This machine is prewired to operate on a 110V power supply circuit that has a verified ground and meets the following requirements: M1001 6" x 26" Vertical Mill Grounding & Plug Requirements This machine MUST be grounded. In the event of certain malfunctions or breakdowns, grounding reduces the risk of electric shock by providing a path of least resistance for electric current. ELECTRICAL For 110V operation: This machine is equipped with a power cord that has an equipment-grounding wire and a grounding plug (similar to the figure on the right). The plug must only be inserted into a matching receptacle (outlet) that is properly installed and grounded in accordance with all local codes and ordinances. For 220V operation: The plug specified under “Circuit Requirements for 220V” on the previous page has a grounding prong that must be attached to the equipmentgrounding wire inside the included power cord. The plug must only be inserted into a matching receptacle (similar to the figure on the right) that is properly installed and grounded in accordance with all local codes and ordinances. Improper connection of the equipment-grounding wire can result in a risk of electric shock. The wire with green insulation (with or without yellow stripes) is the equipment-grounding wire. If repair or replacement of the power cord or plug is necessary, do not connect the equipment-grounding wire to a live (current carrying) terminal. Check with a qualified electrician or service personnel if you do not understand these grounding requirements, or if you are in doubt about whether the tool is properly grounded. If you ever notice that a cord or plug is damaged or worn, disconnect it from power, and immediately replace it with a new one. Extension Cords We do not recommend using an extension cord with this machine. If you must use an extension cord, only use it if absolutely necessary and only on a temporary basis. Extension cords cause voltage drop, which may damage electrical components and shorten motor life. Voltage drop increases as the extension cord size gets longer and the gauge size gets smaller (higher gauge numbers indicate smaller sizes). Any extension cord used with this machine must contain a ground wire, match the required plug and receptacle, and meet the following requirements: Minimum Gauge Size.................................. 12 AWG Maximum Length (Shorter is Better).................50 ft. -12- 110V GROUNDED 5-15 RECEPTACLE Grounding Prong 5-15 PLUG Neutral Hot Figure 1. Typical 5-15 plug and receptacle. GROUNDED 6-15 RECEPTACLE Current Carrying Prongs 6-15 PLUG Grounding Prong Figure 2. Typical 6-15 plug and receptacle. Serious injury could occur if you connect the machine to power before completing the setup process. DO NOT connect to power until instructed later in this manual. Voltage Conversion The voltage conversion MUST be performed by a qualified electrician. To perform the voltage conversion, install the correct plug and rewire the motor to the new voltage, according to the provided wiring diagram. If the diagram included on the motor conflicts with the one in this manual, the motor may have changed since the manual was printed. Use the diagram provided on the motor. M1001 6" x 26" Vertical Mill SETUP Unpacking The SHOP FOX® Model M1001 has been carefully packaged for safe transporting. If you notice the machine has been damaged, please contact your authorized SHOP FOX® dealer immediately. Inventory The following is a description of the main components shipped with the SHOP FOX® Model M1001. Lay the components out to inventory them. Wooden Box Contents (Figures 3 & 4) Qty A. Milling Machine.............................................1 B.Toolbox.......................................................1 Inventory parts not shown: • Power Feed Instruction Manual..........................1 If any parts are missing, find the part number in the back of this manual and contact Woodstock International, Inc. at (360) 734-3482 or at tech-support@shopfox.biz SET UP Qty Toolbox Contents (Figure 4) C. 3" Shell Mill with Arbor....................................1 D.Handwheels..................................................2 E. Handwheel Handles........................................4 F. Drawbar with Locking Nut................................1 G. Spare V-Belts................................................2 H. 230V ON/OFF Switch.......................................1 I. Open End Wrenches 17/19mm & 12/14mm............2 J. T-Slot Bolts M12-1.75 x 40................................2 K.Screwdriver..................................................1 L. Phillips Head Screwdriver.................................1 M. Hex Wrenches 3, 4, 5, & 6mm...........................4 Figure 3. Model M1001. B L C G M K I H E J D F Figure 4. Toolbox contents. NOTICE When ordering replacement parts, refer to the parts list and diagram in the back of the manual. SUFFOCATION HAZARD! Immediately discard all plastic bags and packing materials to eliminate choking/suffocation hazards for children and animals. -13- M1001 6" x 26" Vertical Mill SET UP Machine Placement • Floor Load: Your vertical mill has a large weight load of 822 lbs. in a small footprint. We recommend placing this mill on a concrete floor. • Working Clearances: Consider existing and anticipated needs, size of material to be processed through the machine, and space for auxiliary stands, work tables or other machinery when establishing a location for your vertical mill (see Figure 5). • Lighting: Lighting should be bright enough to eliminate shadow and prevent eye strain. • Electrical: Electrical circuits must be dedicated or large enough to handle amperage requirements. Outlets must be located near each machine, so power or extension cords are clear of high-traffic areas. Follow local electrical codes for proper installation of new lighting, outlets, or circuits. Cleaning Machine The table and other unpainted parts of your Vertical Mill are coated with a waxy grease that protects them from corrosion during shipment. Clean this grease off with a solvent cleaner or citrus-based degreaser. DO NOT use chlorinebased solvents such as brake parts cleaner or acetone—if you happen to splash some onto a painted surface, you will ruin the finish. NEVER use gasoline or other petroleum-based solvents to clean with. Most have low flash points, which make them extremely flammable. A risk of explosion and burning exists if these products are used. Serious personal injury may occur if this warning is ignored! 60" ALWAYS work in wellventilated areas far from possible ignition sources when using solvents to clean machinery. Many solvents are toxic when inhaled or ingested. Use care when disposing of waste rags and towels to be sure they DO NOT create fire or environmental hazards. 41" Figure 5. M1001 minimum working clearances. USE helpers and power lifting equipment to lift this 6" x 26" Vertical Mill. Otherwise, serious personal injury may occur. -14- M1001 6" x 26" Vertical Mill Mounting Mill on Shop Floor Although not required, it is recommend that you mount your new mill to the floor. Because this is an optional step and floor materials may vary, floor mounting hardware is not included. Generally, you can either bolt your machine to the floor or mount it on machine mounts. Both options are described below. Whichever option you choose, it will be necessary to use a precision level to level your mill (see Figures 6-8). Bolting to Concrete Floors Lag shield anchors with lag bolts and anchor studs are two predominate methods for anchoring an object to a concrete floor. We suggest you research the many options and methods for mounting your mill and choose the best that fits your specific application. Figure 6. Typical lag shield anchor and lag bolt. SET UP Using Machine Mounts Using machine mounts gives the advantage of fast leveling and vibration reduction. The large size of the foot pads distributes the weight of the machine to reduce strain on the floor. NOTICE Anchor studs, as shown in Figure 7, are stronger and more permanent alternatives to lag shield anchors; however, they will stick out of the floor, which may cause a tripping hazard if you decide to move your machine at a later point. Figure 7. Typical anchor stud. Figure 8. Machine mount example. -15- M1001 6" x 26" Vertical Mill Assembly The Model M1001 comes fully assembled from the factory with the exception of one of the longitudinal handwheels and the cross handwheel. The head has been rotated to reduce the overall dimension of the shipping crate. Nuts 2 & 3 Hidden from View Headstock Adjustment Loosen the three nuts at the column and rotate the headstock to the "0" position on the column scale (see Figure 10). SET UP Handle Installation The longitudinal and cross handwheels shown in Figure 11 need to be installed. The handwheel handles will need to be installed on all the handwheels. Attach the handwheels and handles with the hex wrench, screwdriver, and hardware provided. Figure 10. Headstock lock nuts. Longitudinal Handwheel Drawbar Cross Handwheel Open the top cover and insert the drawbar into the splined spindle located in the center of the front cone pulley (see Figure 12). Single Shot Lubrication Unscrew the filler cap and fill the reservoir with nondetergent SAE-20 or similar way oil. Manually pump the lever until resistance from the oil pressure is felt (see Figure 9). Knee Feed Figure 11. Handwheel locations. Drawbar Figure 12. Drawbar location. Figure 9. Single shot lubrication system. -16- M1001 6" x 26" Vertical Mill Spindle Controls Figure 13 shows the location of the ON/OFF buttons and the SPINDLE DIRECTION toggle for the Model M1001. • The ON/OFF buttons control power to the spindle. • The SPINDLE DIRECTION toggle will change the direction the spindle rotates. DO NOT change spindle rotation until spindle has come to a complete stop! ON/OFF Spindle Direction Test Run Complete this process once you have familiarized yourself with all instructions in this manual and you have made sure the machine is completely lubricated as described in Lubrication on Page 27. The purpose of the test run is to make sure the motor is working properly before proceeding. 1. Make sure there are no obstructions around or underneath the spindle. 2. Set the mill to the slowest RPM. See Page 23 for adjusting RPM. 3. Put on safety glasses, and make sure any bystanders are wearing safety glasses and are out of the way. 4. Plug the machine into the power outlet and push the ON/OFF switch to turn the mill ON, but make sure that your hand stays over the switch. The mill should run smoothly, with little or no vibration or rubbing noises. • If you hear squealing or grinding noises, turn the machine OFF immediately. Wait for the mill to stop moving, unplug the machine, and correct any problems before further operation. • If the source of an unusual noise or vibration is not readily apparent, contact our technical support for help at (360) 734-3482 or contact us online at tech-support@shopfox.biz. -17- NOTICE Follow spindle break in procedures on Page 24 after the test run and before performing any operations with this machine! Failure to follow the break-in procedures included in this manual may lead to shortened tool life and may void warranty. SET UP To begin the test run procedure, do these steps: Figure 13. Spindle controls. M1001 6" x 26" Vertical Mill OPERATIONS General The Model M1001 will perform many types of operations that are beyond the scope of this manual. Many of these operations can be dangerous or deadly if performed incorrectly. The instructions in this section are written with the understanding that the operator has the necessary knowledge and skills to operate this machine. If at any time you are experiencing difficulties performing any operation, stop using the machine! If you are an inexperienced operator, we strongly recommend that you read books, trade articles, or seek training from an experienced vertical mill operator before performing any unfamiliar operations. Above all, your safety should come first! READ and understand this entire instruction manual before using this machine. Serious personal injury may occur if safety and operational information is not understood and followed. DO NOT risk your safety by not reading! OPERATIONS Positioning Spindle Head The spindle head can be rotated vertically 45˚ both ways, and can rotate horizontally on the column 45˚ in both directions. To rotate the spindle head vertically, do these steps: 1. UNPLUG THE MILL! 2. Make sure the spindle is stopped and the work area is free from obstructions before proceeding. Always wear safety glasses when operating the mill. Failure to comply may result in serious personal injury. 3. Loosen the four nuts that lock the headstock in place with a 17mm wrench (see Figure 14 on next page). 4. Rotate the headstock to the desired angle. 5. Tighten the spindle locking nuts. Note: Additional setup tools should be used to determine the precise angle of the spindle head. DO NOT investigate problems or adjust the mill while it is running. Wait until the machine is turned off, unplugged and all working parts have come to a complete stop before proceeding! -18- M1001 6" x 26" Vertical Mill To rotate the spindle head horizontally, do these steps: Vertical Lock Nuts 1. UNPLUG THE MILL! 2. Make sure the spindle is stopped and the work area is free from obstructions before proceeding. 3. Using a 17mm wrench, loosen the three locking nuts shown in Figure 14. 4. Push or pull the spindle head to swivel it to the desired position. Use the scale located on the column to set the angle desired. 5. Tighten the three nuts to lock the headstock in position. Horizontal Lock Nuts Figure 14. Vertical and horizontal headstock lock nuts. Table Travel Longitudinal Feed Control Longitudinal Locks Figure 15. Longitudinal locks. The longitudinal feed is controlled by two handwheels, one at each end of the table, and can be locked in position by the two locks at the front of the table (see Figure 15). Knee Lock Cross Feed The cross feed is controlled by the center handwheel, and can be locked in position by the lock under the left side of the mill table (see Figure 16). Knee Feed The knee feed is controlled by one handle, just off center at the front of the machine. The Model M1001 has one knee feed lock on the left side of machine next to the single shot pump, where the knee meets the ways (see Figure 16). -19- Cross Lock Figure 16. Cross and knee locks. OPERATIONS The table can be moved in 3 axes. Each axis is independently controlled by a handle or handwheel. The longitudinal travel has the added feature of a power feed, which will be explained in more detail later. Each handle or handwheel has a graduated dial to accurately position the workpiece in relation to the cutting tool. Each axis has the ability to be locked in position. Locking the axis in place will help keep workpiece vibration to a minimum. M1001 6" x 26" Vertical Mill Graduated Dials The table handwheels and the knee handle have graduated dials. Each mark represents 0.001" of movement and one full revolution equals 0.100" The graduated dials float and can be indexed or "zeroed" by loosening the knurled head thumb screw, rotating the graduated dial to "0", and securing the setting with the knurled head thumb screw (see Figure 17). Example: Suppose you want to drill a series of holes with 1/2" centers (0.500"). After locating the first hole placement and drilling, you would zero the graduated dial of the appropriate axis, set the knurled head thumb screw, move the table 0.500" in the appropriate direction and drill the next hole. Figure 17. Graduated dial. Power Feed Controls OPERATIONS This mill comes equipped with a power feed on the longitudinal travel. The power feed has the following controls (see Figure 18 for items A–D, and see Figure 19 for items E–F): For additional information, please refer to the power feed manual supplied with this mill. B C A A. Right/Left Feed Selector—Switch the lever to the left or the right for the desired travel direction. The table should come to a complete stop before changing directions. B. Rapid Speed Switch—Pressing this switch will cause the table to feed at its maximum rate until it is released. C. Feed Setting Dial—Setting from 0 (no travel) to 10 (fastest travel). D Figure 18. Power feed controls. F D. ON/OFF Switch—Delivers power to the power feed. E. Limit Switch—Stops the power feed when it makes contact with the power feed stops. E F. Power Feed Stops—Adjustable stops trigger the limit switch and shuts OFF the power feed when the table is at the end of its travel. Figure 19. Limit switch and power feed stops. -20- M1001 6" x 26" Vertical Mill Quill Travel Quill Feed Control Pinch Bolt The quill feed is controlled by the quill feed handle shown in Figure 20. The handle allows the mill to operate as a drill. To use the quill feed handle, do these steps: 1. Pull the quill feed handle (see Figure 20) forward to feed the quill down towards the workpiece. The quill feed handle is spring loaded to assist in returning the handle to the upmost vertical position. 2. Lock the quill in place at any depth by tightening the quill feed handle lock shown in Figure 20. Note: When the quill feed is not in use, return it to the upmost position and lock in place. This will help maintain mill rigidity and accuracy. Quill Lock Quill Feed Handle Figure 20. Quill feed controls. Quill Clutch Knob 3. Adjust the position of the handle by loosening the pinch bolt on the quill shaft and then tightening when the handle is in the desired position. The micro-feed handwheel is used to accurately control the quill depth (see Figure 21). Micro-feed Handwheel To use the micro-feed handwheel, do these steps: 1. Turn the mill OFF and allow the spindle to come to a complete stop. 2. Tighten the quill clutch knob. 3. Turn the micro-feed handwheel (see Figure 21) clockwise to feed the quill down or counterclockwise to feed the quill up. -21- Figure 21. Micro-feed controls. OPERATIONS Micro-feed Depth Adjustment M1001 6" x 26" Vertical Mill Determining Needed RPM Before changing speeds, you must first determine the best RPM to use with the material and diameter of your cutting tool. Using this determined RPM, you can then set the mill to match that speed. Workpiece Material Cutting Speed (SFM) Aluminum & Alloys 300 To determine the RPM needed for your workpiece, do these steps: Brass & Bronze 150 Copper 100 1. Use the chart in Figure 22 to determine the cutting speed for your workpiece material. Cast Iron, soft 80 Cast Iron, hard 50 Mild Steel 90 Cast Steel 80 Alloy Steel, hard 40 Tool Steel 50 Stainless Steel 60 Titanium 50 Plastics 300-800 2. Measure the diameter of your cutting tool in inches. 3. Use the following formula in Figure 23 to determine the best RPM for your operation. Note: Always round to the closest RPM given on the spindle speed chart. Example 1 You have a piece of aluminum stock, and you are using a 1/2" diameter HSS cutting tool. OPERATIONS Cutting Speeds for High Speed Steel (HSS) Cutting Tools* Wood 300-500 *For carbide cutting tools, double the cutting speed. These values are a guideline only. Refer to the current edition of MACHINERY'S HANDBOOK for more detailed information. Figure 22. Cutting speed chart for HSS cutting tools. Step 1: 300 (SFM from chart) x 4 = 1200 Step 2: 1200 / .5" (Diameter of cutting tool) = 2400 RPM Result: The best speed for this workpiece is 2400 RPM. Example 2 You have a piece of stainless steel, and you are using a 1" diameter carbide cutting tool. Step 1: 60 (SFM from chart) x 2 (for carbide tool) = 120 Step 2: 120 (determined SFM) x 4 = 480 Step 3: 480 / 1" (Diameter of cutting tool) = 480 RPM Result: The best speed for this workpiece is 480 RPM. -22- Figure 23. Formula to determine required RPM. M1001 6" x 26" Vertical Mill Setting RPM Setting the RPM on the Model M1001 involves placing the V-belts on the pulleys as shown in the spindle speed chart below. Motor Release Lever To set the spindle speed, do these steps: 1. Examine the Spindle Speed Chart in Figure 24 to find the closest match to your needed RPM. 2. UNPLUG THE MILL! 3. Open the pulley cover. 4. Loosen the motor release lever and move the motor toward the spindle to loosen the tension on the V-belts. 5. Move the belts to the appropriate pulley combinations as shown on the spindle speed chart below. 6. Tension the V-belts by pulling the motor back and locking the motor release lever (see Figure 25). Spindle Pulley Motor Pulley Idler Pulley A B C I D II III Spindle RPM A B I 730 II 1600 1280 III 2760 2220 C D 360 240 520 1320 Figure 24. M1001 Spindle speed chart in RPMs. -23- Failure to follow RPM and feed rate guidelines may threaten operator safety from ejected parts or broken tools. NOTICE Failure to follow RPM and feed rate guidelines will put undue strain on moving parts, shorten tool life, and create poor workpiece results. OPERATIONS 7. Close the pulley cover and plug in the mill. Figure 25. Applying tension to V-belts. M1001 6" x 26" Vertical Mill Spindle Break-in Procedure 5.Turn ON the spindle in the forward rotation and let it run for a minimum of 10 minutes. Complete this process once you have familiarized yourself with all instructions in this manual and have made sure the machine is completely lubricated. 6. Turn the spindle OFF, wait for the spindle to come to a complete stop. NOTICE 7. Set the SPINDLE DIRECTION toggle to the reverse position and turn the spindle ON. Run the spindle in the reverse direction for 10 minutes. 8. Repeat these steps for each RPM setting. The spindle break-in procedure is important for ensuring long life and trouble-free performance from your mill. Failure to perform this proceedure can shorten the life of your machine and void your warranty. To break-in the spindle, do these steps: 1. Make sure the mill has been properly lubricated. OPERATIONS 2. Make sure there are no obstructions around or underneath the spindle. 3. Set the spindle speed to the lowest RPM. 4. Set the SPINDLE DIRECTION toggle to the forward position. -24- M1001 6" x 26" Vertical Mill Installing Tools To load a tool in the spindle, do these steps: 1. UNPLUG THE MILL! 2. Turn the mill OFF, allow it to come to a complete stop and unplug the mill. Drawbar 3. Clean any debris from the spindle opening. 4. Insert the tool holder or a collet into the spindle. 5. Rotate the holder until the groove lines up with the key and the holder slides into the spindle. 6. Use a wrench to tighten the drawbar (see Figure 26) until the tool is secure in the spindle. Note: Do not overtighten the drawbar. Overtightening makes collet removal difficult and causes unnecessary wear to the draw bar threads, collet, and the spindle taper. 7. Close the pulley cover and clear all items away from the cutting tool before turning the mill ON. To remove cutting tools, do these steps: 1. UNPLUG THE MILL! 2. Make sure the spindle is turned OFF and the quill is at the upmost position. 3. Use a brush to remove any debris or chips from the tool and the tool holder/arbor. 4. Use a wrench to loosen the drawbar from the tool. 5. Once the tool is loosened, support the cutter with a gloved hand, and strike the drawbar with a dead blow hammer or rubber mallet to release the tool holder from the spindle. Note: DO NOT strike the drawbar if it is completely unscrewed from the tool. This can damage the threads on the drawbar and the tool. 6. Finish unscrewing the drawbar by hand. 7. Clean any debris from the spindle opening area. -25- NOTICE DO NOT overtighten the drawbar. Overtightening makes collet removal difficult and causes damage to the drawbar threads, collets, and spindle taper. NOTICE When not in use, always remove collets and cutting tools from spindle taper. Failure to do so may cause the collet to seize and be very hard to remove later. OPERATIONS Removing Cutting Tools Figure 26. Drawbar location. M1001 6" x 26" Vertical Mill MAINTENANCE General Regular periodic maintenance on your SHOP FOX® mill will ensure optimum performance. Make a habit of inspecting your mill each time you use it. Check for the following conditions and repair or replace when necessary: • • • • • • • Loose chucks and arbors. Loose vices or clamps. Loose mounting bolts. Worn switch and safety shut off features. Worn or damaged cords and plugs. Damaged V-belt. Any other condition that could hamper the safe operation of this machine. A thorough cleaning, on a regular basis, will increase the machine durability and efficiency by removing chips and grime that can gum up moving parts. A regular application of a protective spray coating will keep the table and other bare metal parts from rusting and pitting. MAINTENANCE Cleaning Cleaning the Model M1001 is relatively easy. Sweep excess metal chips from the table and ways, and wipe off the remaining waste with a dry cloth. If any coolant is left on the table, wipe it up with a rag. Treat all unpainted cast iron and steel with a non-staining lubricant after cleaning. Table and Base Protect the unpainted cast iron surfaces by wiping them clean after every use—this ensures moisture does not remain on bare metal surfaces. Keep exposed cast iron rust-free with regular applications of surface lubricants designed for cast iron. Remove vices, clamps, rotary tables, etc. after use so moisture cannot be trapped between the components and cause rust. -26- MAKE SURE that your machine is unplugged during all maintenance procedures! If this warning is ignored, serious personal injury may occur. M1001 6" x 26" Vertical Mill Lubrication Power Feed The power feed uses SAE 40 oil and should not need to be changed unless the unit is being repaired. Knee Screw Single Shot Lubrication System Use the single shot lubrication system to oil the ways, the crossfeed screw, and the longitudinal screw by pumping the handle on the reservoir 2-4 times each day (see Figure 27). Fill the reservoir regularly with ISO 68 or SAE 20 weight machine oil. Figure 27. Single shot lubrication system. Knee Elevating Screw Apply liberal amounts of lithium or graphite based grease using a brush or shop rag to the entire length of the knee elevating screw. Drawbar Splines Drawbar Splines Place five drops of ISO 68 or SAE 20 weight machine oil on the splines around the drawbar once a week. This is accomplished by moving the quill all the way down and locking it in place. Apply the oil to the splines on the back side of the drawbar hole. Next, run the quill through complete motion a couple of times to lubricate splines (see Figure 28). Figure 28. Drawbar splines. MAINTENANCE -27- M1001 6" x 26" Vertical Mill Maintenance Schedule Daily: • Pump handle of the one shot lubrication system 2-4 times. • Clean machine to remove debris. • Make sure table/vise is clean and free of metal chips. • Clean spindle openings before inserting tools. • Check for any unsafe conditions. Weekly: • Place five drops of oil on the drawbar splines. • Thoroughly clean the machine ways to remove chips and debris. • Clean and grease the longitudinal, cross, and knee lead screws. Monthly: • Clean/vacuum dust buildup from the motor. • Check mill for level, correct if necessary. Every Six Months: • Inspect belts for wear, and replace as needed. Maintenance Notes DATE MAINTENANCE PERFORMED MAINTENANCE -28- M1001 6" x 26" Vertical Mill SERVICE General This section covers the most common service adjustments or procedures that may need to be made during the life of your machine. Always disconnect your machine from the power source before performing any service! If you require additional machine service not included in this section, please contact Woodstock International Technical Support at (360) 734-3482 or send e-mail to: tech-support@shopfox.biz. Figure 29. Cross gib screw. MAKE SURE that your machine is unplugged during all service procedures! If this warning is ignored, serious personal injury may occur. Gibs The gibs are pre-adjusted at the factory and should not need further adjustment until many hours of machine use, if ever. If the movement seems too tight, make sure that the locks are fully released, ways are free of chips and debris and are thoroughly lubricated with oil. Figure 30. Longitudinal gib screw. Adjust the gibs by a combination of loosening or tightening the adjustment screws until a slight drag is felt while moving the table/knee along the dovetail slides. There are two adjustment screws, one on each end of the gib (see Figures 29-31 for the locations of the adjustment screws). The chip wiper guards must be removed to access some of the gib adjustment screws. -29- SERVICE When adjusting the gibs, the goal is to take out unnecessary play in the table and cross slide without causing the slides to bind. Loose gibs may cause poor finishes on the workpiece and may cause undue wear on the slide. Over-tightening may cause premature wear to the gib. Figure 31. Knee gib screw. M1001 6" x 26" Vertical Mill Adjusting Backlash Backlash is the amount of play found in a leadscrew. It can be found by turning the cross slide handwheel in one direction, and then turning the handwheel the other direction. When the cross slide begins to move, the backlash has been taken up. Adjustment Cap Screws Leadscrews are adjusted for backlash at the factory and should not need any adjustment for many hours of machine use, if ever. Keeping a clean and well lubricated machine will ensure long leadscrew life. To adjust the backlash, do these steps: Longitudinal Nut Longitudinal Feed Adjustment Figure 32. Longitudinal nut. 1. Slightly tighten the two cap screws on the longitudinal nut (see Figure 32). DO NOT overtighten. 2. Rotate the handwheel in both directions to see if backlash has been reduced or eliminated. There should only be a slight drag when turning the handwheel. Note: If the cap screws are too tight, it will cause excessive wear to the longitudinal nut and leadscrew, which could lead to costly repairs. Cross Nut Adjustment Cap Screws Crossfeed Adjustment 1. Slightly tighten the two cap screws on the cross nut (see Figure 33). DO NOT overtighten. 2. Rotate the handwheel in both directions to see if backlash has been reduced or eliminated. There should only be a slight drag when turning the handwheel. Note: If the cap screws are too tight, it will cause excessive wear to the cross nut and leadscrew, which could lead to costly repairs. SERVICE -30- Figure 33. Cross nut. M1001 6" x 26" Vertical Mill Electrical Safety Instructions These pages are current at the time of printing. However, in the spirit of improvement, we may make changes to the electrical systems of future machines. Study this diagram carefully. If you notice differences between your machine and these wiring diagrams, call Woodstock International Technical Support at (360) 734-3482. 1. SHOCKHAZARD. 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! 5. MOTORWIRING. 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. 6. 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. 2. QUALIFIEDELECTRICIAN. Due to the inherent hazards of electricity, only a qualified electrician should perform wiring tasks on this machine. If you are not a qualified electrician, get help from one before attempting any kind of wiring job. 3. WIRECONNECTIONS. 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. 4. WIRE/COMPONENTDAMAGE. 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 completing the task. 7. CAPACITORS/INVERTERS. Some capacitors and power inverters store an electrical charge for up to five minutes after being disconnected from the power source. To avoid being shocked, wait at least this long before working on these components. 8. ELECTRICALREQUIREMENTS. You MUST follow the electrical requirements at the beginning of this manual when connecting your machine to a power source. 9. EXPERIENCINGDIFFICULTIES. If you are experiencing difficulties understanding the information included in this section, contact our Technical Support at (360) 7343482. WIRING DIAGRAM COLOR KEY BLUE WHITE BROWN GREEN GRAY YELLOW YELLOW GREEN PURPLE RED ORANGE PINK -31- LIGHT BLUE BLUE WHITE TURQUOISE SERVICE The photos and diagrams included in this section are best viewed in color. You can view these pages in color at www.shopfox.biz. BLACK M1001 6" x 26" Vertical Mill Electrical Parts Identification DZ47LE C32 Contactor Read Page 31 STOP DZ47 Contactor Before Wiring Move wire to position A for 220V operation. A Transformer Terminal Bar Wiring Box SERVICE Figure 34. M1001 Electrical panel. -32- M1001 6" x 26" Vertical Mill Wiring Diagram 265 VAC 150�F Capacitor Contactor 110V (230V) 110V (230V) 2A Starter U1 Reverse Switch Z2 24V,40W V2 Z1 Motor 400 VAC 20 ±5 �F Capacitor Figure 37. M1001 Wiring schematic. Figure 35. Motor wiring box currently wired for 110V. Read Page 31 STOP Jumpers Red Black Before Wiring Red Black 110V wiring for motor Red Jumpers Black Black Red 230V wiring for motor SERVICE Figure 36. Motor wiring for 110V or 230V. Also refer to Figure 37. NOTICE If you find the spindle rotates in the opposite direction as indicated by the switch, reverse the position of the two black power wires. -33- M1001 6" x 26" Vertical Mill Troubleshooting This section covers the most common problems. WARNING! DO NOT make any adjustments until the mill is unplugged and all moving parts have come to a complete stop. SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Motor will not start. 1. Tripped circuit breaker or relay inside machine wiring box or power source breaker box. 2. Low voltage. 3. Open circuit in motor or loose connections. 4. Switch at fault. 5. Faulty start capacitor. 1. Reset circuit breaker by flipping switch on then off then back on. Reset relay by pressing the reset button located on the face. 2. Check power supply for proper voltage. 3. Inspect all lead connections on motor and magnetic switch for loose or open connections. 4. Replace switch. 5. Replace start capacitor. Fuses or circuit breakers trip open. 1. Short circuit in line cord or plug. 1. Inspect cord or plug for damaged insulation and shorted wires and replace extension cord. 2. Inspect all connections on motor for loose or shorted terminals or worn insulation. 3. Install correct fuses or circuit breakers. 2. Short circuit in motor or loose connections. 3. Incorrect fuses or circuit breakers in power supply. Motor overheats. 1. Motor overloaded. 2. Air circulation through the motor restricted. 1. Reduce load on motor. 2. Clean out motor to provide normal air circulation. Tool slips in collet. 1. Collet is not fully drawn up into spindle taper. 2. Wrong size collet. 1. Snug up draw bar. 4. Taking too big of a cut. 2. Measure tool shank diameter and match with appropriate diameter collet. 3. Remove all oil and debris from collet and spindle taper. 4. Lessen depth of cut and allow chips to clear. Breaking tools or cutters. 1. RPM and or feed rate is too fast. 2. Cutting tool getting too hot. 3. Taking too big of a cut. 1. Use tables to set correct RPM and feed rates. 2. Use cutting fluid or oil for appropriate application. 3. Lessen depth of cut and allow chips to clear. Machine is loud when cutting. Overheats or bogs down in the cut. 1. Excessive depth of cut. 2. Dull cutting tools. 1. Decrease depth of cut. 2. Use sharp cutting tools. Workpiece vibrates or chatters during operation. 1. Table locks not tight. 2. Spindle lock not tight. 3. Workpiece not securely clamped to table or into mill vice. 4. RPM and feed rate too high. 1. Tighten down table locks. 2. Tighten spindle lock. 3. Check that clamping is tight and sufficient for the job. Make sure mill vice is tight to the table. 4. Use appropriate RPM and feed for the job. Table hard to move. 1. Table locks are tightened down. 2. Chips have loaded up on bedways. 1. Make sure table locks are fully released. 2. Frequently clean away chips that load up during milling operations. 3. Lubricate bedways and handles. SERVICE 3. Debris in collet or in spindle taper. 3. Bedways are dry and in need of lubrication. 4. Longitudinal stops are interfering. Bad surface finish. 5. Gibs are too tight. 4. Check to make sure that stops are floating and not hitting the center stop. 5. Loosen gib screw(s). 1. Wrong RPM or feed rate. 2. Dull cutting tool or poor cutting tool selection. 3. Wrong rotation of cutting tool. 1. Adjust for appropriate RPM and feed rate. 2. Sharpen cutting tool or select a better cutting tool for the intended operation. 3. Check for proper cutting rotation for cutting tool. -34- M1001 6" x 26" Vertical Mill Headstock Assembly 151 152 153 2 151 152 39 41 38 40 56 71 57 71 58 70 54 168 55 39 169 73-4 59 72 73-3 10 137 17 50 16 27 170 28 49 26 42 11 46 9 138 4 48 47 69 73-5 61 36 37 13 73 67 66 60 15 12114 12 70 68 51 25 62 65 70 53 128 22 23 49 34 31 32 33 3 29 30 63 73-2 19 21 172 73-1 20 45 24 53 35 18 53 52 136 8 5 44 43 171 6 113 PARTS 7 13 -35- M1001 6" x 26" Vertical Mill Base Assembly 84 144 86 85 126 125 77 127 83 76 91 130 79 75 128 119 143 92 90 89 77 132 108 144 86 78 130 81 13 82 98 127 136 12280 120 96 91 93 90 94 131 129 110 106 128 84 83 120 85 109 144 104 127 80 103 105 138 123 86 49 128 80 122 83 67 117 80 122 110 120 120 128 125 97 131 95 139 84 85 86 144 102 127 99 100 115 88 87 74 157 163 141 166 165 135 138 134 140 158 123 133 164 118 111 87 88 133 142 112 159 160 161 162 69 139 173 72 114 148 116 149 155 150 156 146 PARTS 147 -36- 167 175 174 M1001 6" x 26" Vertical Mill Machine Parts Lists DESCRIPTION REF PART # DESCRIPTION VERTICAL MILLING HEAD BELT HOUSING COVER QUILL INT RETAINING RING 75MM LOCK WASHER 30MM VERTICAL SPINDLE COVER BEARING ADJUSTING NUT SPINDLE SLEEVE PULLEY LOCKING NUT SPINDLE PULLEY QUILL PINION SHAFT PHP HD SCREW M5-.8 X 10 CLUTCH WORM GEAR CLUTCH CLUTCH ADJUSTING NUT CLUTCH COVER PINION SHAFT SEAT HANDLE SHAFT COLLAR HAND LEVER WORM SHAFT WORM SHAFT SLEEVE BEARING LOCKNUT M14 x 1.5 DIAL DIAL POSITIONING SCREW HANDWHEEL HANDLE QUILL LOCKING BLOCK QUILL LOCKING BOLT QUILL STOP MICRO SCREW MICROMETER NUT QUILL MICRO STOP NUT QUILL STOPPER HEX HEAD BOLT M8-1.25 x 20 FLAT WASHER 8MM DRAW BAR C5 x 15 RIVET PHL HD SCREW M5-.8 x 10 COVER SUPPORTING ARM HEX NUT M5-.8 FLAT WASHER 72MM BEARING 7207 BALL BEARING 6007ZZ BALL BEARING 6206ZZ BEARING COVER INT RETAINING RING 75MM BALL BEARING 6009Z THRUST BEARING 1052 50 51 52 53 54 55 56 57 58 59 60 61 62 63 65 66 67 68 69 70 71 72 73 73-1 73-2 73-3 73-4 73-5 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 COIL SPRING COIL SPRING INT RETAINING RING 19MM CAP SCREW M6-1 x 15 SWIVEL ARM SWIVEL STUD INT RETAINTING RING 35MM PULLEY PIVOT STUD V-BELT PULLEY V-BELT PULLEY MOTOR MOUNT MOTOR SUSPENDING PIVOT MOTOR MOUNT BELT TENSIONING LOCK SCREW BELT TENSIONING SPRING VERTICAL HEAD ADAPTER STUD M12-1.75 X 35 FLAT WASHER 10MM V-BELT A-35 4L350 HEX NUT ACORN M12-1.75 BALL BEARING 6003Z V-BELT A-31 4L310 MOTOR 1.5 HP 4 POLE-1725 MOTOR COVER MOTOR FAN CAPACITOR 20MFD 400V CAPACITOR 150MFD 250VAC JNCTN BOX & CPCTR COVER COLUMN TABLE TABLE GIB GIB ADJUSTING SCREW LONGITDNL BEARING BRACKET LONGITUDINAL LEAD SCREW BEARING NUT M20 x 15 LONGITUDINAL FEED NUT CAP SCREW M5-.8 x 25 DIAL DIAL POSITIONING SCREW HANDWHEEL HANDWHEEL HANDLE LONGITDNL ADJUSTING SCREW ADJUSTING SCREW SLEEVE TABLE STOPPER TABLE LOCKING SCREW HANDLE BAR SADDLE SADDLE GIB WAY COVER XM1001001 XM1001002 XM1001003 XPR67M XPLW15M XM1001006 XM1001007 XM1001008 XM1001009 XM1001010 XM1001011 XM1001012 XPS09M XM1001014 XM1001015 XM1001016 XM1001017 XM1001018 XM1001019 XM1001020 XM1001021 XM1001022 XM1001023 XM1001024 XM1001025 XM1001026 XM1001027 XM1001028 XM1001029 XM1001030 XM1001031 XM1001032 XM1001033 XM1001034 XPB09M XPW01M XM1001037 XM1001038 XPS09M XM1001040 XPN06M XM1001042 XP7207 XP6007ZZ XP6206 XM1001046 XPR67M XP6009 XM1001049 -37- XM1001050 XM1001051 XM1001052 XPSB28M XM1001054 XM1001055 XM1001056 XM1001057 XM1001058 XM1001059 XM1001060 XM1001061 XM1001062 XM1001063 XM1001064 XM1001066 XM1001067 XM1001068 XPVA35 XPN26M XP6003 XPVA31 XM1001073 XM1001073-1 XM1001073-2 XPC20A XPC150A XM1001073-5 XM1001074 XM1001075 XM1001076 XM1001077 XM1001078 XM1001079 XM1001080 XM1001081 XPSB38M XM1001083 XM1001084 XM1001085 XM1001086 XM1001087 XM1001088 XM1001089 XM1001090 XM1001091 XM1001092 XM1001093 XM1001094 PARTS REF PART # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 M1001 6" x 26" Vertical Mill REF PART # DESCRIPTION REF PART # DESCRIPTION 95 96 97 98 99 100 102 103 104 105 106 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 125 126 127 128 129 130 131 132 133 134 135 CROSS LEAD SCREW CROSS FEED NUT CROSS FEED BEARING BRACKET STOP BLOCK STOP BLOCK FIXTURE CROSS ADJUSTING SCREW KNEE KNEE GIB KNEE LOCKING SCREW GEAR SHAFT SLEEVE GEAR SHAFT ELEVATING HANDLE CLUTCH HANDLE ARM ELEVATING GEAR ELEVATING LEAD SCREW ELEVATING LEAD SCREW NUT CHIP GUARD BASE ON/OFF SWITCH 110V ON/OFF SWITCH 230V LIGHT RUBBER SHEET CAP SCREW M6-1 X 25 BALL BEARING 6004ZZ KEY 6 X 6 X 15 FLAT WASHER 45MM CAP SCREW M6-1 X 15 BALL BEARING 6004ZZ EXT RETAINING RING 20MM OIL CUP KEY 5 X 5 X 20 CAP SCREW M5-.8 X 10 CAP SCREW M6-1 X 45 CAP SCREW M6-1 X 15 EXT RETAINING RING 20MM CAP SCREW M6-1 X 20 COVER PHLP HD SCR M6-1 X 8 136 138 139 140 141 142 143 144 146 147 148 149 150 151 152 153 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 CAP SCREW M8-1.25 X 25 KEY 7 X 7 X 20 FLEXIBLE CONDUIT WIRE WIRING TERMINAL CONNECTOR FLAT WASHER 6MM SHOULDER BOLT M10-1.5 X 74 BASE CABINET DOOR LATCH HEX BOLT M10-1.5 X 40 FLAT WASHER 10MM BARBED HOSE FITTING PHLP HD SCR M5-.8 x 8 HINGE SAFETY SWITCH T-BOLTS M12-1.75 X 40 SHELL MILL 3" POWER FEED UNIT SINGLE SHOT OILER HEX WRENCH 3MM HEX WRENCH 4MM HEX WRENCH 5MM HEX WRENCH 6MM OPEN END WRENCH 17/19MM OPEN END WRENCH 12/14MM SCREWDRIVER PHILLIPS HEAD SCREWDRIVER TOOLBOX CAP SCREW M6-1 X 35 PULLEY BASE SHOULDER BOLT M8-1.25 X 60 PHLP HD SCR M4-.7 x 6 HEX NUT M10-1.5 CONTACTOR DZ47 CONTACTOR DZ47L TRANSFORMER PARTS XM1001095 XM1001096 XM1001097 XM1001098 XM1001099 XM1001100 XM1001102 XM1001103 XM1001104 XM1001105 XM1001106 XM1001108 XM1001109 XM1001110 XM1001111 XM1001112 XM1001113 XM1001114 XM1001115 XM1001116 XM1001117 XM1001118 XPSB06M XP6004 XPK99M XPW22M XPSB28M XP6004 XPR09M XM1001127 XPK34M XPSB50M XPSB30M XPSB28M XPR09M XPSB02M XM1001134 XPS03M -38- XPSB31M XPK25M XM1001139 XM1001140 XM1001141 XM1001142 XPW03M XM1001144 XM1001146 XM1001147 XPB31M XPW04M XM1001150 XPS05M XM1001152 XM1001153 XM1001155 XM1001156 XM1001157 XM1001158 XPAW03M XPAW04M XPAW05M XPAW06M XPWR1719 XPWR1214 XM1001165 XM1001166 XM1001167 XPSB48M XM1001169 XM1001170 XPS17M XPN02M XM1001173 XM1001174 XM1001175 M1001 6" x 26" Vertical Mill Machine Labels 202 203 204 201 205 206 207 203 208 REF PART # DESCRIPTION REF PART # DESCRIPTION 201 XLABEL-09 ENTANGLEMENT LABEL 205 XLABEL-07 DISCONNECT LABEL 202 D3375 SHOPFOX LOGO SMALL 206 XLABEL-08 READ MANUAL LABEL 203 XLABEL-14 ELECTRICITY LABEL 207 XLABEL-11 SAFETY GLASSES LABEL 204 XM1001204 MACHINE ID LABEL 208 XM1001208 MODEL NUMBER LABEL -39- PARTS Safety labels warn about machine hazards and how to prevent machine damage or injury. The owner of this machine MUST maintain the original location and readability of all labels on this machine. If any label is removed or becomes unreadable, REPLACE that label before allowing the machine to enter service again. Contact Woodstock International, Inc. at (360) 734-3482 or www. shopfoxtools.com to order new labels. WARRANTY WARRANTY Woodstock International, Inc. warrants all Shop Fox machinery to be free of defects from workmanship and materials for a period of two years from the date of original purchase by the original owner. This warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence or accidents, lack of maintenance, or reimbursement of third party expenses incurred. Woodstock International, Inc. will repair, replace, or arrange for a dealer refund at its expense and at its option, the Shop Fox machine or machine part, which in proper and intended use has proven to be defective, provided that the original owner returns the product prepaid to an authorized warranty or repair facility as designated by our Bellingham, Washington office with proof of their purchase of the product within two years, and provides Woodstock International, Inc. reasonable opportunity to verify the alleged defect through inspection. If it is determined there is no defect, or that the defect resulted from causes not within the scope of Woodstock International Inc.'s warranty, then the original owner must bear the cost of storing and returning the product. This is Woodstock International, Inc.’s sole written warranty and any and all warranties that may be implied by law, including any merchantability or fitness, for any particular purpose, are hereby limited to the duration of this written warranty. We do not warrant that Shop Fox machinery complies with the provisions of any law, acts or electrical codes. We do not reimburse for third party repairs. In no event shall Woodstock International, Inc.’s liability under this limited warranty exceed the purchase price paid for the product, and any legal actions brought against Woodstock International, Inc. shall be tried in the State of Washington, County of Whatcom. We shall in no event be liable for death, injuries to persons or property or for incidental, contingent, special or consequential damages arising from the use of our products. Every effort has been made to ensure that all Shop Fox machinery meets high quality and durability standards. We reserve the right to change specifications at any time because of our commitment to continuously improve the quality of our products. M1001 6" x 26" Vertical Mill Warranty Registration Name____________________________________________________________________________________ Street___________________________________________________________________________________ City__________________________ State____________________________Zip_________________________ Phone #_______________________ Email___________________________Invoice #____________________ Model #_________Serial #______________Dealer Name__________________Purchase Date___________ The following information is given on a voluntary basis. It will be used for marketing purposes to help us develop better products and services. Of course, all information is strictly confidential. 1. How did you learn about us? ______ Advertisement ______ Mail Order Catalog ______ Friend ______ Website 2. How long have you been a woodworker/metalworker? ______ 2-8 Years _____ 8-20 Years ______ 0-2 Years ______ 20+ Years 3. How many of your machines or tools are Shop Fox®? ______ 0-2 ______ 3-5 _____ 6-9 ______ 10+ 4. Do you think your machine represents a good value? CUT ALONG DOTTED LINE _____ Local Store _____ Other: ______ Yes _____ No 5. Would you recommend Shop Fox® products to a friend? ______ Yes _____ No 6. What is your age group? ______ 20-29 ______ 50-59 ______ 30-39 ______ 60-69 7. What is your annual household income? ______ $20,000-$29,000 ______ $30,000-$39,000 ______ $50,000-$59,000 ______ $60,000-$69,000 _____ 40-49 _____ 70+ _____ $40,000-$49,000 _____ $70,000+ 8. Which of the following magazines do you subscribe to? ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ Cabinet Maker Family Handyman Hand Loader Handy Home Shop Machinist Journal of Light Cont. Live Steam Model Airplane News Modeltec Old House Journal ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ Popular Mechanics Popular Science Popular Woodworking Practical Homeowner Precision Shooter Projects in Metal RC Modeler Rifle Shop Notes Shotgun News ____ ____ ____ ____ ____ ____ ____ ____ ____ Today’s Homeowner Wood Wooden Boat Woodshop News Woodsmith Woodwork Woodworker West Woodworker’s Journal Other: 9.Comments:___________________________________________________________________ _ _____________________________________________________________________________ _ _____________________________________________________________________________ _ _____________________________________________________________________________ _ _____________________________________________________________________________ FOLD ALONG DOTTED LINE Place Stamp Here WOODSTOCK INTERNATIONAL INC. P.O. BOX 2309 BELLINGHAM, WA 98227-2309 FOLD ALONG DOTTED LINE TAPE ALONG EDGES--PLEASE DO NOT STAPLE
advertising