Hafco Metalmaster BM-67HV User manual

INSTRUCTION MANUAL
BM-67HV
Turret Milling Machine - Horizontal - Vertical (415V)
(X) 1000mm (Y) 300mm (Z) 400mm
M621D
Page 1
Instruction Manual for BM-67HV (M621D)
02/10/2014

CONTENTS
1. Safety instruction
2. Working environment and note of caution symbol
3. Usage and structure
4. Operation
5. Transmission and changing speed system
6. Main parameter
7. Bearing list
8. Adjustment
9. Coolant and lubrication
10.Transport installation and trial run
11. Maintenance
12. Simple malfunction & obviation
13. Electrical system
14. Accuracy list
15. Packing list
Page 2
Instruction Manual for BM-67HV (M621D)
02/10/2014

1 Safety Instruction
1. 1 GENERAL SAFETY RULES
Operator must read the instruction carefully before operating the
machine, and the manager of safety department should assure the
operator knows the requirements well.
1.1.1 The operation, maintenance and repair of the machine must be done
by qualified person who have been trained to have the ability to forecast the
potential risks. Only safety-conscious persons who are fully aware of the risks
can operate the machine.
1.1.2 To those people who assemble, operate, or maintain the machine
must be confirmed to have read and understood the operating instructions.
1.1.3 After stopping the machine, the tool will still run for a period of
time due to inertia, do not open the tool guard and touch the tool with your
hand before it comes to stop running.
1.1.4 Do not detach or modify any part of the safety guard. The machine
should be disconnected from the power supply during maintenance or repair.
WARNING! NEVER CONTACT THE CUTTERS AND OTHER
DRIVING PARTS WITH HANDS IF THEY ARE STILL MOVING
1.1.5 Assign special persons to operate, maintain and adjust the
machine.
1.1.6 Operate the machine in technically perfect condition. Only the
Page 3
Instruction Manual for BM-67HV (M621D)
02/10/2014

producer or qualified person can completely repair the machine.
1.1.7 Stop the machine immediately if abnormal phenomena appear,
check and repair the machine by specialized persons in time.
1.1.8 Disassembly and assembly the machine with the hoisting
equipment, which is of enough load capacity.
1.1.9 Observe all safety instructions and warnings attached to the
machine, make sure they are always complete and perfectly legible.
1.1.10 Do safety inspection before operating. Ensure the stroke limit
switches, stop block and emergency stop button safe and reliable.
1.1.11Reinstall the removed guards and safety devices in place after
maintaining.
1.1.12 Do maintenance or adjustment only after switching the machine
off and disconnecting the machine from the power source.
1.1.13 Always keep children away from the machine. Operating
personal must be at least 18 years old.
1.1.14 Do not wear loose clothing, gloves, neckties or jewelry (rings,
watches, etc). Keep the sleeves and the edges of the work uniform tight.
Always be sure to wear safety goggles and wear safety shoes during
operation.
1.1.15 Put the long hair into a safety hat during operation no matter the
operator is a man or a woman.
1.1.16 It is recommended to wear suitable hearing protection
equipment when necessary to reduce the risk of hearing loss.
1.1.17 Provide adequate light around the machine, and keep the
perimeter around the machine dry, clean and in good order. In addition, do
not place anything near the machine; otherwise it becomes an obstacle
Page 4
Instruction Manual for BM-67HV (M621D)
02/10/2014

during operation.
1.1.18 Do not remove the guards from their working place during
operation.
1.1.19 Disconnect the power supply before leaving the machine.
1.1.20 Restart the machine only after the guards and safety devices are
replaced to their position and in their good function.
1.1.21 Do not place tools, work pieces, or other items, which not be in
use on the machine, especially on the moving parts.
1.1.22 Clamp workpiece and tools completely and reliably and take off
the wrench from chuck before starting the spindle running.
1.1.23 Stop the machine before adjusting the position of the coolant
nozzles.
1.1.24 Do not use compressed air to remove dust and chips etc.
deposited on the machine, switchboard, control unit etc.
1.1.25 Both operators and the maintenance men should read the
descriptions carefully on the caution plate attached on the machine. They
should observe the OPERATION MANUAL in their work. During
operation and maintenance, care should be taken so that this caution plate is
not dirtied or damaged.
1.1.26 Always bear in mind where the emergency stop button is so that
you can operate it without delay in case of an emergency.
1.1.27 Start the machine according to the starting procedures strictly.
1.1.28 Keep your hands away from the moving parts of the machine
during operation.
1.1.29 When removing chips caught around the tooling system, avoid
taking them out directly by hand, there is cutting hazards. It is safer with
Page 5
Instruction Manual for BM-67HV (M621D)
02/10/2014

proper tool when doing this. Be sure to stop the machine when removing
chips from the machine.
1.1.30 Prior to starting test operation, read this manual carefully so as
to be familiar with this machine.
1.1.31 Contact the manufacturer if for some reason the OPERATION
MANUAL should become unreadable.
1.1.32 When install a tool, stop the spindle and the feed in each axis.
1.2 Additional Safety Rules For Milling Machine
1.2.1 Read and understand the entire instruction manual before operating the
machine.
Warning: Failure to comply with this instruction may cause serious injury.
1.2.2 Always wear approved safety glasses/suit while operating machine
tool.
1.2.3 Make certain the machine is properly grounded.
1.2.4 Before operating the machine, remove tie, rings, watches, other
jewelry, Keep the sleeves and the edges of the work uniform tight. Always
be sure to wear safety goggles and wear safety shoes during operation. Do
not wear gloves while operating machine tool.
1.2.5 Keep the floor around the machine clean and away from scrap
materials, oil and grease , etc.
1.2.6 Keep all guards of the machine securely in place at all times when
working. For maintenance purpose, use extreme caution and replace the guards
immediately after maintenance.
1.2.7 Make sure workpiece and cutter be fitted and clamped well, and make
sure the cutter doesn't touch the workpiece before starting up the machine.
1.2.8 Must shut off power supply before adjusting or maintaining the
machine.
Page 6
Instruction Manual for BM-67HV (M621D)
02/10/2014

1.2.9 The operator must keep clear-minded when operating the machine and
pay attention to what he is doing. It is not allowed to operate the machine when
the operator is tired, after drinking or taking medicines.
1.2.10 Use tools properly. Don't force a tool or an attachment to do work
which was not designed. Sharp tools should be used. Deformed or dull tools
should not be used.
1.2.11 Make certain the motor switch is in OFF position before connecting
the machine with power supply.
1.2.12 Never attempt to operate or adjust the machine when the procedure is
not understood.
1.2.13 be careful, the handle of the spindle sleeve rapidly rebound.
1.2.14 It is advised that the operator should change machining position on
the table frequently in order to prolong the life of the machine.
1.2.15 Lubricate the machine in time according to the lubricating demand.
1.2.16 Keep the electrical elements clean, do not clean the electrical
elements with kerosene or gas.
1.2.17 Be sure that the spindle rotation of the machine comes to rest before
changing spindle speed.
1.2.18 It is forbidden to process flammable and explosive metal, for
example :pure aluminum, magnesium and so on.
1.2.19 The machine should never be used in flammable, explosive or humid
environment
1.2.20 The machine should be disassembled and assembled supported by the
lifting mechanism with sufficient bearing capacity.
1.2.21 Always stop the machine before adjusting the position of the cooling
nozzle.
1.2.22Make sure that the operating site should kept well ventilated. It is
recommended that ventilation equipment should be provided on the operating
site.
1.2.23 The sound pressure of the machines is 75 db (a).
The sound power of the machines is 90 db (a).
Page 7
Instruction Manual for BM-67HV (M621D)
02/10/2014

2. Working environment and note of caution symbol
2.1The milling machine is designed for operating on the site:
—The height above sea level doesn’t exceed 1000m.
—The ambient temperature range doesn’t exceed 5℃～40℃.
—The relative humidity doesn’t exceed 50% within＋40℃and 90%
within＋20℃.
—Transportation temperature range is within -25℃～+55℃
__The light in the working environment should not be lower than 500
lux.
2.2 Do not use the machine in an environment of electric dirt,
explosion, metal fretted, gas and steam which can destroy insulation .
2.3 Do not use the machine in an environment of impact and
vibration.
3. Usage and structure
Page 8
Instruction Manual for BM-67HV (M621D)
02/10/2014

This milling machine is designed for milling, drilling on general metal
workpiece.
Warning: Do not process flammable and explosive metal, e.g. pure
aluminum and magnesium etc.
The machine consists of body, knee, worktable, main transmission structure,
feed box , ram, coolant, lubrication, electric apparatus and so on. ( fig.1)
The structure of the machine:
3.1 The body is composed of knee, base, column , and the column that is
fixed on the base with screws .
3.2 Knee is in front of the column, and is connected with the column
through rectangle guideways, which can lift and lower along vertical
guideway.
3.3 Sliding saddle connects with knee through rectangle guideways.
Worktable connects with sliding saddle through swallowtail guideways, and
the sliding saddle connects with the knee and table. Worktable and the sliding
saddle can be moved by lead screw and screw nut drive.
Page 9
Instruction Manual for BM-67HV (M621D)
02/10/2014

Page 10
Instruction Manual for BM-67HV (M621D)
02/10/2014

3.4 Main transmission adopts gear drive structure .
3.5 The ram consists of ram and hanging frame, the fixed base that is
installed on the column, and is connected with ram through swallowtail ways,
hanging frame locate the forward part of the the ram.
3.6 The feed box is installed at the bottom & at the right of sliding saddle,
and is driven directly by motor,
3.7 The coolant system consists of coolant pump, coolant tube and tank that
is in the base.
3.8 Lubrication system contains immersed oil splash lubrication,
lubrication pump and hand pump lubrication .
3.9 Electric box is in the column, and integarated operation panel is on the
left of the column, which enables convenient operation.
The worktable in the longitudinal and cross directions is moved by manual
feed or power feed, the power feed of the table cross & longitudinal direction
is provided by a feed box. The feed box has eight kinds of feed speed and one
rapid speed. Main transmission adopts gears transmission structure, high
efficiency, big torque, wide speed change range, so expand the working extent.
4. Operation
4.1 Read the manual carefully before operating the machine, make familiar
with structure of the machine, functions of each handle, and buttons, coolant &
lubrication, transmission system and electrical system. (fig.2)
4.2 Check whether lock structure has been loosened before starting the
machine, and whether lifting or lowering movement of spindle sleeve and
electrical equipment are normal, whether grounding wire is corrected and
reliable.
Page 11
Instruction Manual for BM-67HV (M621D)
02/10/2014

Page 12
Instruction Manual for BM-67HV (M621D)
02/10/2014

4.3 Three modes of the spindle sleeve feed : micro feed, power feed, manual
feed
4.3.1 Microfeed
First, make sure handle (6) on the left of the headstock is opposite to the
position of handle (6) in Fig. 1, tighten right handle (5) to make bevel gear in
handle base merge with worm, then turn the handwheel (10) in front of the
headstock to realize the micro feed.
4.3.2 When the handle (5) is loose, two feed modes are provided: power
feed, manual feed
4.3.2.1 Power feed
First, ensure handle (5) is loose, adjust handle (6) to the position according
to fig. 1. There are stopper and travel scale on the headstock, and they are used
to stop spindle and control machining depth. Lockhandle (12) can clamp the
spindle sleeve at any position.
Do not lock the handle when the spindle feeds.
4.3.2.2 Manual feed
Make certain locking handle (5) loosened, turn handle (4) directly to realize
the manual feed.
4.3.3 Before starting the spindle, check whether handle (6) on the left of the
headstock is opposite to the position of handle (6) in fig.1, and whether spindle
quill is loosened, otherwise don't start machine .
4.3.4 Switch on power, check the directions of spindle rotation, coolant
pump rotation direction is consistent with the requirements before operation.
Examine whether power feed travel limit direction is consistent with the
designed direction, otherwise, must adjust the power supply wires . Judge the
vertical spindle turning direction: watch from top to bottom , it is positive
Page 13
Instruction Manual for BM-67HV (M621D)
02/10/2014

direction if the spindle turns clockwise .
4.3.5 No power feed when the spindle reverses.
4.4 Table feed
4.4.1 Feed box is at the bottom & at the right of the sliding saddle, and it is
driven by motor. Speed can be changed through the handle ( 9 ).
4.4.2 Longitudinal table feed handles (14) locate at the two ends of the
table, so the operation is convenient. Table power feed handle (2) is in the
middle of the table, and it controls table stop & table movement( left or right ),
travel stopper( 3 ) is used to limit the position. When working , adjust stopper
( 3 ) to target position and fix.
4.4.3 Table cross feed
Table cross feed structure is in front of the knee.
Manual feed : First, place handle (19) in the middle position, then turn
handle ( 13 ) to move table .
Power feed : Adjust handle (19) up or down, then the table will move
forward & backward.
WARNING:
The speed should be changed only when the machine is in standstill
state.
1. First, place handle (2) and handle (19) in the middle position.
2. Start power feed box motor to keep it run.
3. Adjust handle (9) to proper position to select the proper feed speed .
4. Change handle (2) and handle (19) to the target position to realize
Page 14
Instruction Manual for BM-67HV (M621D)
02/10/2014

power feed.
4.5 Knee
Knee is in front of the column, and is connected with the column through
rectangle guideways. Turn handle (1) to move knee to proper position.
CAUTION: Must loosen lockhandles (21) before moving table.
4.6 Vertical movement of the knee
Automatic lifting and lowering structure is installed on the left of the knee.
Travel of vertical movement of the knee is limited by travel limit switches that
locate at the top and at the bottom of the column
4.6.1 Crank (1) will automatically loosen when the knee feeds
automatically.
4.6.2 When lifting or lowering the knee by hand, please push crank (1) into
the knee, then turn it .
CAUTION:
1. The lock structure of the knee lifting or lowering movement and the
knee power feed adopt interlocking structure, then the knee will not move
when the lockhandle is locked. Must loosen the lockhandle when the knee
moves. And the lockhandle is on the right of the knee.
2. In order to lubricate conveniently, the oil-cups are set on two sides of
the vertical guideways. To prolong machine's life, please often lubricate
the machine with oil-gun.
4.7 Must clamp lockhandle before the machine works. To obtain better
effect, please select vertical milling cutter with tri-blade. Must raise the table
near the spindle nose; while selecting vertical milling cutter with
two-blade ,You’d better select micro feed during operation.
4.8 The headstock can be tilted ±45°in vertical plane.
Page 15
Instruction Manual for BM-67HV (M621D)
02/10/2014

First, loosen locknut no more than 1-2 pitches while tilting, and not too
loose either. turn the worm on the right side of the headstock with spanner
(S21~24), the headstock will tilt to the required position, and finally lock the
locknut and start to work.
4.9 In the horizontal plane, the headstock can be swiveled ±180°around
the vertical column axis. When swiveling , loosen four locknuts at the bottom
of the ram first, and swivel the ram to proper position, then lock the four
locknuts.
4.10 The headstock can be moved in the cross direction. Loosen two
lockhandles on the right side of the ram before moving it, then turn the worm
with spanner to make the headstock and ram move, then clamp the two
lockhandles.
4.11 Swivel the ram 180°when the horizontal milling arbor and hanger
work together .
4.12 Must wear approved safety glasses/face or shields while working.
4.13 Must clean the iron crumbs and dirts, and coat anti-rust oil when
work is over.
4.14 Must shut off power supply when operators find faults during the
operation, please ask technicians to check and repair if necessary.
5. Transmission system
5.1 Main transmission system (Fig. 2)
5.1.1 Vertical spindle:
Power is passed to the spindle through sliding gear .
5.1.2 Horizontal spindle:
Horizontal spindle is driven by the motor, and through belt pulley and gears
Page 16
Instruction Manual for BM-67HV (M621D)
02/10/2014

to horizontal spindle, so horizontal spindle can acquires 12 steps of rotation
speed.
5.2 Speed change
5.2.1 Vertical spindle:
First, shut off the power source before changing the speed , please adjust
handle (20) on the left of the headstock to proper position according to the
illustration of the scutcheon.
5.2.2 Horizontal spindle:
First, cut off the power supply before speed changes, please adjust handle
(16) on the right of the headstock to proper position according to the
instruction of the scutcheon .
Page 17
Instruction Manual for BM-67HV (M621D)
02/10/2014

6. Main parameters
No. Specification Parameter
1 Max. manual drilling dia. φ50mm (1 31/32") ( cast iron )
2 Max. automatic drilling dia. φ12mm (15/32") (cast iron )
φ10mm ( 25/64") (steel)
3 Max. vertical milling dia. φ25 mm( 63/64" )
4 Spindle taper 7:24 ISO40
5 Spindle speed steps 8 setps ( vertical )
12 setps ( horizontal)
6 Spindle speed range 90~2000r.p.m. ( vertical)
38~1310 r.p.m.(horizontal)
7 Vertical. spindle feed capacity 0.08; 0.15; 0.25 3setps mm / round
8 Distance from vertical spindle
to surface of column 780mm ( 30 11/16" )
9 Distance from vertical spindle nose
to table surrface 180mm ~ 580mm (7 5/64")~(22 13/16")
10 Distance from horizontal spindle
center to table surface 70mm ~470mm( 2 3/4" )~( 18 1/2" )
11 Spindle sleeve travel 120mm (4 23/32")
12 Table size 1320mm×320mm (52"×12 19/32" )
13 Table travel
800mm×300mm ( manual )
( 31 31/64" )×( 11 13/16" )
750mm×250mm ( digital readout )
( 29 33/64" )×( 9 27/32" )
14 Lifting and descending travel of the table 400 mm (15 47/64")
15 Main motor power 2.2 KW
16 Overall dimension (L×W×H) 1710mm×1720mm×2330mm
(67 3/8"×67 3/4"×91 3/4")
17 Net weight 1800 Kg
Notice: The specifications are subjected to modifications and improvements
without notice.
Page 18
Instruction Manual for BM-67HV (M621D)
02/10/2014

7. Bearing list of vertical and horizontal spindles (Fig. 3 )
NO. Name Model Qty
1 bearing 32012/P5 1
2 bearing 7008AC/P5 1
3 bearing 16009/P6 1
4 bearing 6208-Z/P6 1
5 bearing 6305/P6 1
6 bearing 6204/P6 1
7 bearing 6304/P6 1
8 bearing 6004-Z/P6 1
9 bearing 61908-RZ/P6 1
10 bearing 6005-Z/P6 1
11 bearing 6004-Z/P6 1
12 bearing 51105 1
13 bearing 61905/P6 1
14 bearing 6202/P6 2
15 bearing 51100 1
16 bearing 6003 2
17 bearing 61805 1
18 bearing 61906 1
19 bearing 2007111/P6 1
20 bearing 7308E/P6 1
21 bearing 205/P6 5
22 bearing 307/P6 1
Page 19
Instruction Manual for BM-67HV (M621D)
02/10/2014

Fig . 3
Page 20
Instruction Manual for BM-67HV (M621D)
02/10/2014