Bridgeport Series I User manual

INSTALLATION, OPERATION,
MAINTENANCE, AND PARTS LIST
SERIES I
MILLING MACHINES
Revised: May 21, 2010
Manual No. M-450A Litho in U.S.A.
Part No. M A-0009500-0450 March, 2009
TP5260

Information in this manual is subject to change without notice.
This manual covers installation, operation, maintenance, and parts list for
Bridgeport Series I milling machines.
In no event will Hardinge Inc. be responsible for indirect or consequential
damage resulting from the use or application of the information in this man-
ual.
Reproduction of this manual, in whole or in part, without written permis-
sion of Hardinge Inc. is prohibited.
ORDERING REPLACEMENT PARTS
Please provide the following information when ordering replacement parts:
1. The complete machine serial number. The machine serial number tag is located on the
power case door.
2. List the following:
A. Manual Number (M-450A).
B. Page Number.
C. Item Number.
D. Part Description.
E. Part Number.
F. Quantity of each part required.
3. Specify how and where to ship.
- NOTICE -
Bridgeport is a registered trademark of Hardinge Inc.
© 2009, Hardinge Inc. M-450A

SAFETY
To prevent serious bodily injury, you should observe the following basic safety precautions when
installing, operating or servicing the milling machine.
1. Follow all instructions in the manual.
2. Wear approved industrial safety glasses and safety shoes.
3. Do not wear gloves, long sleeves, long hair, rings, watches, jewelry or other items that
could become caught in moving parts.
4. Keep all parts of your body away from moving parts (belts, cutters, gears, etc.)
5. Use proper point of operation safeguarding.
These and other safety precautions are discussed in the American National Standard Institute
standard entitled safety requirements for the construction, care, and use of drilling, milling, and
boring machines (ANSI B11-8-1983).
This publication is available from:
American National Standards Institute
25 West 43rd Street, 4th floor
New York, NY 10036
Safeguarding for protection at the point of operation can only be designed and constructed when
the parameters of the particular operation have been determined. As a result, ANSI B11.8-1983,
Section 5.1, states that “it shall be the responsibility of the employer to provide, and ensure use of, a
guard, guarding device, awareness barrier, awareness device, or shield…”
To assist machine users in designing point of operation safeguarding for their specific machine
applications, the Occupational Safety And Health Administration has published a booklet entitled
Concepts and Techniques of Machine Safeguarding (OSHA Publication No. 3067).
This publication is available from:
The Publication Office – OSHA
U.S. Department of Labor
200 Constitution Avenue, NW
Washington, D.C. 20210
The general purpose point of operation shield provided with this machine and shown in certain
illustrations throughout this manual may not be appropriate and cannot be utilized for all possible
applications of the machine. Use additional or alternate safeguarding where this shield is not
appropriate or cannot be utilized. Note that for purposes of display, the shield has been removed in
certain other illustrations in this manual.
M-450A i

WARNINGS, CAUTIONS, AND NOTES
- WARNING -
Warning notices are used in this publication to emphasize that hazardous
mechanical conditions, voltages, currents, or temperatures exist in this
equipment which could cause serious personal injury and/or damage to the
equipment.
- CAUTION -
Caution notices are used where equipment might be damaged if care is not
taken.
In situations where inattention could cause either personal injury or damage to the equipment, a
warning notice is used.
- NOTE -
Notes merely call attention to information that is especially significant in under-
standing and operating the equipment.
This document is intended for the use of those who install, operate and maintain the milling
machine. Although reasonable care has been exercised in the preparation of this manual to make it
complete and accurate, this manual does not purport to cover all conceivable problems or
applications pertaining to this machine.
ii M-450A

SAFETY RECOMMENDATIONS
DO NOT OPERATE EQUIPMENT until you have read and understood the appropriate opera-
tor and safety maintenance manuals.
DO NOT OPERATE EQUIPMENT until you have read and understood all machine and con-
trol key signs.
DO NOT OPERATE EQUIPMENT for the first time without a qualified instructor. Consult your
supervisor when in doubt as to the correct way to perform an operation.
DO NOT OPERATE EQUIPMENT unless proper maintenance has been regularly performed
and the equipment is known to be in good working order.
DO NOT ALLOW the operation or repair of equipment by untrained personnel.
WARNING or INSTRUCTION TAGS are mounted on the equipment for your safety and infor-
mation. Do not remove them.
DO NOT OPERATE EQUIPMENT if any unusual or excessive heat, noise, smoke, or vibra-
tion occurs. Report any excessive or unusual vibration, sounds, smoke, or heat as well as any
damaged parts.
WEAR SAFETY GLASSES with side shields and SAFETY SHOES with steel toes and oil-re-
sistant soles at all times. When necessary, wear respirator, helmet, and ear muffs or plugs.
DO NOT OPERATE ANY MACHINE while wearing rings, watches, jewelry, loose clothing,
neckties, or long hair not contained by a net or shop cap.
DO NOT WEAR GLOVES while operating equipment. Gloves are easily caught in moving
parts.
REMOVE ANY LOOSE PARTS OR TOOLS left on machine or in the work area before oper-
ating the machine. Always check the machine and work area for loose tools and parts, espe-
cially after work has been completed by maintenance personnel.
REMOVE CHUCK WRENCHES before starting the machine.
NEVER OPERATE A MACHINE after taking strong medication, using non-prescription drugs
or consuming alcoholic beverages.
SAFEGUARD THE CUTTING ZONE (“point of operation”). Use standard, general purpose
safeguards when possible. Use special safeguards when required.
PROTECT YOUR HANDS. Stop the spindle completely before changing tools.
PROTECT YOUR HANDS. Stop the spindle completely before loading or unloading a
workpiece.
DO NOT REMOVE CHIPS with hands. Use a hook or similar device and make certain that all
machine movements have ceased.
DO NOT ADJUST tooling, workpieces or coolant hoses while the machine is running.
PROTECT YOUR HANDS. Stop the spindle completely before taking measurements.
PROTECT YOUR HANDS. Stop the spindle completely before opening safeguards or covers.
NEVER REACH around a safeguard.
M-450A iii

PROTECT YOUR HANDS. Stop the machine before changing or adjusting belts, pulleys or
gears.
PROTECT YOUR HANDS. Keep hands and arms clear of spindle start switch when changing
tools.
PROTECT YOUR EYES AND THE MACHINE. Never use a compressed air hose to remove
chips.
KEEP WORK AREA WELL LIGHTED. ask for additional light if needed.
DON’T SLIP. Keep your work area clean and dry. Remove chips, oil and obstacles.
NEVER LEAN ON your machine. Stand away when the machine is running.
MAKE CERTAIN that you are clear of any “pinch points” created by moving slides before
starting the machine.
PREVENT OBJECTS from flying loose. Securely clamp and locate workpiece. Use stop
blocks where necessary. Keep clamps clear of cutter path.
PREVENT CUTTER BREAKAGE. Use correct table feed and spindle speed for the job. Re-
duce feed and speed if you notice unusual noise or vibration.
PREVENT CUTTER BREAKAGE. Rotate spindle in clockwise direction for right-hand tools,
counterclockwise for left-hand tools. Use the correct tool for the job.
PREVENT WORKPIECE and cutter damage. Never start the machine when the cutter is in
contact with the workpiece.
DO NOT USE worn or defective tools. Use the proper size and type of tool for the task at
hand.
KEEP ROTATING CRANKS AND HANDWHEELS well lubricated and maintained. Do not re-
move safety springs.
CERTAIN MATERIALS, such as magnesium, are highly flammable in dust and chip form. See
your supervisor before working with these materials.
PREVENT FIRE. Keep flammable liquids and materials away from work area and hot chips.
PREVENT MACHINE from moving unexpectedly. Disengage power feed when not being used
(manual machines only).
PREVENT MACHINE from moving unexpectedly. Always start machine in manual mode.
UNLESS OTHERWISE NOTED, all operating and maintenance procedures are to be per-
formed by one person. To avoid injury to yourself and others, be sure that all personnel are
clear of the machine when opening or closing the coolant guard door and any access covers.
iv M-450A

INSTALLATION AND USE OF SAFEGUARDS
Both American National Standard B11.8 and OSHA Section 1910.212 assign responsibility for
point of operation safeguarding of milling machines to the employer/user. Therefore, to prevent
serious injury resulting from the rotating cutter, flying chips, or splashing coolant, point of operation
safeguarding should be used on milling machines to the greatest extent practicable.
This booklet provides basic information for the installation and use of the general purpose
safeguard. It also contains the names of several manufacturers of other types of point of operation
safeguarding for vertical milling machines.
Remember, point of operation safeguarding is your responsibility as the employer/user. You are in
the best position to evaluate your safeguarding needs and ensure that the proper safeguards are
installed and used.
- CAUTION -
A safety shield is supplied for protection from chips and coolant with every
machine.
The chip and coolant shields have been designed and are custom manufac-
tured with the highest clear impact material commercially available:
polycarbonate (G.E. Lexan). It has an impact strength 5 to 10 times greater
than acrylic (plexiglass) or butyrate (UVEX) materials, thereby offering the
greatest protection for our customers.
Some of the new “easy to dispose of” coolants and/or cutting oils contain
chemicals harmful to polycarbonate. These chemicals are:
Mono-ethanolamine, Di-ethanolamine, Tri-ethanolamine and the combination
thereof. These chemicals may significantly reduce the impact strength of the
shield within days, and could destroy the entire shield in weeks.
Use of use of coolants and/or cutting oils containing these chemicals will
void the warranty on your safety shield, and could cause injury to your work-
ers.
- WARNING -
This safeguard DOES NOT take the place of any other safety practice or
safety equipment.
YOU MUST ALWAYS wear safety glasses and safety shoes.
YOU MUST ALWAYS stop the spindle of the machine completely before
changing or adjusting the workpiece, fixture, or tool.
YOU MUST NEVER wear gloves, long sleeves, long hair, rings, watches,
neckties, jewelry or other loose items.
M-450A v

GENERAL PURPOSE SAFEGUARDS
There is no single safeguard which can match the versatility of the Series I machine. As a result,
you will find that the guard assemblies shown in Figures I.I and I.II, like all safeguards, will be suitable
for some operations, but not for others. Carefully analyze the operation to be performed before
deciding whether this safeguard is suitable. Adjust the guard to suit your special requirements. If you
find that it is not suitable for a particular application, you should use an alternate form of protection.
Installation for Machines with R-8 Spindle Taper
If the machine was manufactured on or after January 1, 1983, the manufacturer has drilled and
tapped two holes in the nose cap of the spindle to be used for mounting the guard (the two untapped
holes serve to remove the nose cap with a spanner wrench).
1. Place the mounting ring (Item 11) underneath the top of the guard (Item 7).
2. Place two socket head cap screws (Item 12) through the holes in ring, and hand-start them
into the threaded holes in the nose cap until hand tight.
3. Align guard to be square with table of machine (unless angular mounting is desired).
4. Tighten screws with a hex wrench.
Retrofits
If the machine was manufactured prior to January 1, 1983, you must retrofit as follows:
1. Manually tap the existing spanner wrench holes with a .250”-20 bottoming tap.
- CAUTION -
There is no need to drill new holes or deepen the existing holes. Attempts at
either practice may result in spindle damage.
2. Mount the guard as indicated above.
vi M-450A
Revised: May 21, 2010
Figure I.I - Spindle Guard Assembly
(R8 Spindle)
1
TP5262A
2
9
3,4,5
6
7
8
10
11
12

Machines with Erickson #30 Quick Change or Universal #200 Quick Change Spindles
If the machine was manufactured after January 1, 1985 and has either an Erickson #30 or a
Universal #200 quick change spindle, the manufacturer has drilled and tapped four #8-32 holes in the
nose cap of the spindle for mounting the guard.
ERICKSON SPINDLE
1. Remove the spindle locknut. This is done by removing the long button head black finish screw,
which is normally left of the cadmium-finished button head screw on the locknut of the spindle.
This will allow you to unscrew the locknut by turning it counter-clockwise.
- NOTE -
Observe the orientation of the mounting holes in the spindle and the mounting ring
to orient the quill guard as desired.
2. Place the mounting ring (Item 11) on the top of the guard (Item 7).
3. Place the locking ring (Item 12) underneath the top of the guard (Item 7).
4. Secure the two rings together with four #8-32 x 5/8 button head cap screws.
5. Lower the quill.
6. Position the guard under the spindle.
7. Use four #8-32 x 1/2 button head cap screws to secure the guard to the spindle.
8. Reinstall the quick change locknut. Refer to assembly instructions.
UNIVERSAL #200 QUICK CHANGE SPINDLES
The quick change locknut is not to be removed. To install the spindle safeguard, follow the
preceding steps listed above: 2, 3, 4, 5, 6, and 7.
M-450A vii
Revised: May 21, 2010
Figure I.II - Spindle Guard Assembly
(#30 Quick Change or Universal
#200 Quick Change Spindle)
TP5263A
1
2
3,4,5
6
7
8
9
10
11
12
13
14

BP 11060813 – R-8 Shield Assembly
Refer to Figure I.I.
Item Part Number Description Qty
1 BP 11191203 Shield Assembly, Rear 1
2 BP 11010060 Screw, Hand 8-32 x .500 4
3 0300312 Screw, BHC 10-32 x .750 4
4 BP 11010065 Washer, Plastic #10-32 8
5 BP 11010055 Nut, Stop, #10-32 (Elastic) 4
6 BP 11060824 Shield, Right Side 1
7 BP 11060817 Shield Assembly, Top 1
8 BP 11010063 Screw, Drive, "Type U" #12 x .625 2
9 BP 11060820 Shield Assembly, Front 1
10 BP 11060822 Shield, Left Side 1
11 BP 11191201 Ring, Guard Mounting 1
12 0100610 Screw, SHC 1/4-20 x 5/8 2
BP 11060814 – Quick Change Shield Assembly
Refer to Figure I.II.
Item Part Number Description Qty
1 BP 11191203 Shield Assembly, Rear 1
2 BP 11010060 Screw, Hand 8-32 x .500 4
3 0300312 Screw, BHC 10-32 x .750 4
4 BP 11010065 Washer, Plastic #10-32 8
5 BP 11010055 Nut, Stop, #10-32 (Elastic) 4
6 BP 11060824 Shield, Right Side 1
7 BP 11060816 Shield Assembly, Top 1
8 BP 11010063 Screw, Drive, "Type U" #12 x .625 2
9 BP 11060820 Shield Assembly, Front 1
10 BP 11060822 Shield, Left Side 1
11 BP 12190330 Ring, Guard Mounting 1
12 BP 12190331 Ring, Guard Locking 1
13 0300208 Screw, BHC #8-32 x 1/2 4
14 0300210 Screw, BHC #8-32 x 5/8 4
viii M-450A
Revised: May 21, 2010