South Bend SB1027 - Manuals

-4- For Machines Mfg. Since 8/09 Model SB1027 I N T R O D U C T I O N Full View Identification Figure 1. SB1027 full view identification. Drive System & Headstock (See Page 5 for Identification) Coolant Nozzle & Valve X-Axis Ball Handle Coolant Return Hose One- Shot Oiler Z-Axis Crank Y-Axis...

-6- For Machines Mfg. Since 8/09 Model SB1027 I N T R O D U C T I O N Machine Specifications Model SB1027 9" x 48" EVS Milling Machine w/Coolant System & Power Feed Product Dimensions: Weight ...................................................................................................

For Machines Mfg. Since 8/09 Model SB1027 -9- S A F E T Y 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 conditi...

For Machines Mfg. Since 8/09 Model SB1027 -11- S A F E T Y Additional Milling Machine Safety 6. Stopping Spindle: To reduce the risk of hand injuries or entanglement hazards, DO NOT attempt to stop the spindle with your hand or a tool. Allow the spindle to stop on its own or use the spindle brake. 7...

-12- For Machines Mfg. Since 8/09 Model SB1027 P R E P A R A T I O N Preparation Overview Things You'll Need During the setup process, operation, and maintenance of your machine, you'll need the following items: For Lifting • A forklift or other power lifting device rated for the weight of the machi...

For Machines Mfg. Since 8/09 Model SB1027 -13- 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 con...

-14- For Machines Mfg. Since 8/09 Model SB1027 P R E P A R A T I O N 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...

For Machines Mfg. Since 8/09 Model SB1027 -15- P R E P A R A T I O N = Power connection 63" 36" 24" 38" 83 1 ⁄ 2 " 23" 30" Wall W all 30" Figure 4. Clearances. Weight Load Refer to the Machine Specifications for the weight of your machine. Make sure that the surface u...

For Machines Mfg. Since 8/09 Model SB1027 -17- P R E P A R A T I O N Bolting to Concrete Floors Leveling & Mounting Leveling Figure 6. Example of a precision level. Leveling machinery helps precision components, such as bed ways, remain straight and flat during the lifespan of the machine. Compo...

-18- For Machines Mfg. Since 8/09 Model SB1027 P R E P A R A T I O N Assembly Ball Handles The ball handles for the X-axis leadscrew have spring-loaded, keyed center bushings, as shown in Figure 8. This allows them to disengage from the leadscrew when using the power feed, avoiding an entanglement h...

For Machines Mfg. Since 8/09 Model SB1027 -19- P R E P A R A T I O N Way Covers 1. Remove the five button-head cap screws shown in Figure 10 from the front of the saddle and knee, position the pleated way cover in place, then secure it with the removed cap screws. Figure 10. Front way cover installe...

-20- For Machines Mfg. Since 8/09 Model SB1027 P R E P A R A T I O N 5. Loosen the hose clamp screws above the coolant return screens in the base (see Figure 13 on the previous page), insert the hoses so that they will drain into the screens, then re-tighten the clamp screws to secure them in place....

For Machines Mfg. Since 8/09 Model SB1027 -21- P R E P A R A T I O N 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 ...

For Machines Mfg. Since 8/09 Model SB1027 -25- 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 ho...

-26- For Machines Mfg. Since 8/09 Model SB1027 O P E R A T I O N Control Panel Use Figures 17–18 and the following descriptions to understand the functions of the mill main power switch and the control panel. Main Power Switch: When turned ON , enables power to flow to the control panel. Figure 17. ...

For Machines Mfg. Since 8/09 Model SB1027 -27- O P E R A T I O N Table Movement The mill table moves in three directions, as illustrated in Figure 19: • X-axis (longitudinal) • Y-axis (cross) • Z-axis (vertical) These movements are controlled by table ball handles and the Z-axis crank. Additionally,...

For Machines Mfg. Since 8/09 Model SB1027 -29- O P E R A T I O N Head Movement The mill head tilts 45° back and forth, and rotates 90° left and right, as shown in Figures 23–24. Figure 24. Head tilts 90° left-and-right. 90° Figure 23. Head tilts 45° back-and-forth. 45° Tool Needed Qty Wrench 19mm .....

-30- For Machines Mfg. Since 8/09 Model SB1027 O P E R A T I O N Rotating Head 1. DISCONNECT MILL FROM POWER! 2. Loosen the four rotation lock bolts on the face of the head shown in Figure 26. 3. Use one hand to apply pressure to the head in the direction of rotation, then slowly turn the rotation b...

For Machines Mfg. Since 8/09 Model SB1027 -33- O P E R A T I O N 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 M...

-34- For Machines Mfg. Since 8/09 Model SB1027 O P E R A T I O N Setting Spindle Speed Setting Spindle Speed Range Setting the spindle speed range involves using a lever to engage/disengage the spindle spline with the bull gear. To set the spindle speed range: 1. DISCONNECT MILL FROM POWER! 2. Use t...

For Machines Mfg. Since 8/09 Model SB1027 -35- O P E R A T I O N 3. Press the spindle speed range lever shown in Figure 34 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 lever is pointing ...

For Machines Mfg. Since 8/09 Model SB1027 -37- O P E R A T I O N 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 39 and the descriptions below to become familiar with these controls. A. Auto-...

-38- For Machines Mfg. Since 8/09 Model SB1027 O P E R A T I O N 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 clu...

For Machines Mfg. Since 8/09 Model SB1027 -39- O P E R A T I O N 7. Select one of the three downfeed rates by pulling the auto-downfeed rate selector knob out, position the selector over the appropriate detent, then release the knob. Make sure the pin is firmly seated by attempting to move the selec...

-40- For Machines Mfg. Since 8/09 Model SB1027 O P E R A T I O N Loading/Unloading Tooling The mill is equipped with an R8 spindle taper and a 1 ⁄ 2 "-20 x 18 1 ⁄ 2 " spindle drawbar, as shown in Figure 43. Figure 43. Spindle drawbar and spacer. Tool Needed Qty Wrench 21mm .....................

For Machines Mfg. Since 8/09 Model SB1027 -41- 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. ! Machine Storage Each operator of this machine is responsible for ensuring proper care of the equipment...

For Machines Mfg. Since 8/09 Model SB1027 -43- M A I N T E N A N C E 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...

-44- For Machines Mfg. Since 8/09 Model SB1027 M A I N T E N A N C E 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...

For Machines Mfg. Since 8/09 Model SB1027 -45- M A I N T E N A N C E Speed Range Bearing Sleeve 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 Fi...

-46- For Machines Mfg. Since 8/09 Model SB1027 M A I N T E N A N C E 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 u...

-48- For Machines Mfg. Since 8/09 Model SB1027 M A I N T E N A N C E Coolant Reservoir A small amount of coolant is lost during normal operation. Check the coolant reservoir regularly and fill it if necessary. We recommend changing the coolant every three months or sooner if it develops an unpleasan...

For Machines Mfg. Since 8/09 Model SB1027 -49- M A I N T E N A N C E 5. Remove the two pump mounting cap screws and move the pump out of the way (see Figure 57). 6. Use rags, scrapers, and cleaning solvent to thoroughly clean out the bottom of the reservoir and the base of the pump. Make sure that t...

-50- For Machines Mfg. Since 8/09 Model SB1027 M A I N T E N A N C E Adjusting Gibs Gibs are tapered lengths of metal between two dovetail sliding surfaces. Gibs control the gap between these surfaces and how they slide past one another. Correctly adjusting the gibs is critical to producing good mil...

For Machines Mfg. Since 8/09 Model SB1027 -51- S E R V I C E Figure 58. Table gib and adjustment screw underneath the left side of the table. Table Gib & Adjustment Screw Figure 59. Saddle gib and adjustment screw. Saddle Gib & Adjustment Screw Figure 60. Knee gib and adjustment screw. Knee ...

-52- For Machines Mfg. Since 8/09 Model SB1027 S E R V I C E 3. Use the T-handle hex wrench or similar tool to rotate the adjustment plate on the leadscrew nut in small increments, then rotate the X-axis ball handle to check the amount of backlash. 4. When you are satisfied with the adjustment, re-t...

For Machines Mfg. Since 8/09 Model SB1027 -53- S E R V I C E 5. Loosen the two cap screws on the face of the leadscrew nut shown in Figure 64. Figure 64. Cross leadscrew nut and cap screws. Cross Leadscrew Nut & Cap Screws 6. Re-install the key onto the leadscrew so that you can use the ball han...

-54- For Machines Mfg. Since 8/09 Model SB1027 T R O U B L E S H O OT I N G 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. 1. Em...

-56- For Machines Mfg. Since 8/09 Model SB1027 E L E C T R I C A L 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 d...

For Machines Mfg. Since 8/09 Model SB1027 -57- E L E C T R I C A L Upper Electrical Panel +V P2 P1 R+ R- S+ S- 1G P C A1 A2 AC AM AC M P MA M B M C S1 S2 S3 S4 S5 S6 S7 H C S C H1 R P Bk Bk 600 W 40 Ohm Thermal Brake Resistor Variable Frequency Drive Yaskawa V1000 CIMR-VT2A0020BAA 200V 3-Ph 5.5kW/3....

-58- For Machines Mfg. Since 8/09 Model SB1027 E L E C T R I C A L Lower Electrical Panel OV 220V 23 0V 3 8 0V 4 6 0V 415V 110V 24V 12V 0V E Yung-Jeng Transformer 500VA A009-0392 5A F use 2A F use 5A F use 1A F use Aux Contactor AB 100F A20 1L1 A1 3L2 5L3 N O13 53NO 63NO 54NO 64NO 24V Cont actor All...

For Machines Mfg. Since 8/09 Model SB1027 -59- E L E C T R I C A L Control Panel Wiring 2 3 W2 U2 COM NC NO 3 NO 4 3 NO 4 3 NO 4 1 NC 2 Emergency S TO P Button Motor O N Button Coolant Switc h Spindel Direction Switc h Spindle Speed Dial Spindle Speed Display X2 X1 3 NO 4 + – + – 1 2 2 2 11 11 10 9 ...

-60- For Machines Mfg. Since 8/09 Model SB1027 E L E C T R I C A L Electrical Component Pictures Figure 66. Control panel wiring. Figure 68. Spindle motor wiring. Figure 69. Spindle brake switch wiring. Figure 70. Coolant pump motor wiring. Figure 67. Electrical panel wiring.

For Machines Mfg. Since 8/09 Model SB1027 -61- P A R T S Headstock 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 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82...

-62- For Machines Mfg. Since 8/09 Model SB1027 P A R T S Headstock Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 1 PSB10240449 ROUND KNOB 3/8-16 50 PSB10240037A CLUSTER GEAR SHAFT 18T/12T 2 PSB10240002 PINION SHAFT LEVER 51 PSB10240037A FEED DRIVE CLUSTER GEAR 23T 3 PSB10240003 PINION SHA...

For Machines Mfg. Since 8/09 Model SB1027 -65- P A R T S Gearbox 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 339 340 341 342 343 344 345 346 347 348 349 306 329 For Reference Only 303A 307A

-66- For Machines Mfg. Since 8/09 Model SB1027 P A R T S Gearbox Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 301 PSB10240301 GEARBOX PLATE 325 PSB10240325 BELT PULLEY GEAR 302 PK70M KEY 8 X 8 X 12 326 PCAP24M CAP SCREW M5-.8 X 16 303A PSB10240303A SPINDLE GEAR HUB ASSEMBLY 327 PSB102403...

For Machines Mfg. Since 8/09 Model SB1027 -67- P A R T S Belt Housing 401 402 403 403-1 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437 438 439 440 441 442 443 444 445 446 447 448 449 450 451 452 453 454 455 456 ...

-68- For Machines Mfg. Since 8/09 Model SB1027 P A R T S Belt Housing Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 401 PSB10270403A MOTOR FAN COVER 433 PW03M FLAT WASHER 6MM 402 PSB10270403A MOTOR FAN 434 PSB10240442 BRAKE BEARING CAP 403A PSB10270403A MOTOR ASSEMBLY 435 PCAP115M BUTTON ...

For Machines Mfg. Since 8/09 Model SB1027 -69- P A R T S Ram For Reference Only 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 522 523 504 504 510 515 517 524 525 526 527 528 529 530 531 532 533 534 535 536 504 531A REF PART # DESCRIPTION REF PART # DESCRIPTION 5...

For Machines Mfg. Since 8/09 Model SB1027 -73- P A R T S Table Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 701 PN01 HEX NUT 1/2-20 725 PSB10240723A TABLE BALL HANDLE CLUTCH ASSY 702 PSB10270723A HANDLE 729 PCAP03M CAP SCREW M5-.8 X 8 703 PSB10240703 CROSS FEED BALL HANDLE 730 PSB1027073...

For Machines Mfg. Since 8/09 Model SB1027 -75- P A R T S Coolant System 901 902 903 904 905 906 907 908 909 910 911 912 913 914 915 916 917 918 905 905 REF PART # DESCRIPTION REF PART # DESCRIPTION 901 PCAP02M CAP SCREW M6-1 X 20 910 PSB10270910 PIPE ELBOW 90 DEG 3/8 X 3/8 PT 902 PW03M FLAT WASHER 6...

-76- For Machines Mfg. Since 8/09 Model SB1027 P A R T S Electric Box & Control Panel 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 1021 1022 1023 1024 1025 1026 1027 1028 1029 1032

For Machines Mfg. Since 8/09 Model SB1027 -77- P A R T S Electric Box & Control Panel Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 1001 PSB10271001 ELECTRIC BOX BACKBOARD 1017 PSB10271017 FUSE HOLDER 4P 1002 PSB10271002 INVERTER YASAKAWA V1000 1018 PSB10271018 TRANSFORMER YUNG-JENG A...

-78- For Machines Mfg. Since 8/09 Model SB1027 P A R T S Tools 1101 1102 1103 1104 1105 1106 1107 REF PART # DESCRIPTION REF PART # DESCRIPTION 1101 PSB10241004 TOOLBOX 1105 PWR1921C CLOSED WRENCH 19/21MM 1102 PSDF2 SCREWDRIVER FLAT #2 1106 PAW1510M HEX WRENCH 10PC 1.5-10 MM 1103 PSDP2 PHLP HD SCREW...

For Machines Mfg. Since 8/09 Model SB1027 -79- P A R T S Machine Labels A REF PART # DESCRIPTION REF PART # DESCRIPTION 1201 PSBLABEL08HL ENTANGLEMENT HAZARD LABEL 1209 PSBLABEL02HL DISCONNECT WARNING LABEL 1202 PSB10271202 LUBRICATION DIRECTION LABEL 1210 PSBLABEL13HL CLOSE DOOR WARNING LABEL 1203 ...

-80- For Machines Mfg. Since 8/09 Model SB1027 P A R T S Machine Labels B 1209 1210 1217 1218 1219 1220 1221 1222 1223 1224 REF PART # DESCRIPTION REF PART # DESCRIPTION 1209 PSBLABEL02HL DISCONNECT WARNING LABEL 1220 PSB10271220 SPEED RANGE LABEL 1210 PSBLABEL13HL CLOSE DOOR WARNING LABEL 1221 PSB1...