MachineryHouse Hafco MetalMaster HM-51B User manual

TURRET MILLING MACHINE
OPERATION MANUAL
Edition No :TM-5154-1
Date of Issue :10/2019
Models.
HM-51B, HM-54GB
Prodcut Code M577, Product Code. M579
HM-51B
HM-54GB
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Instructions Manual for HM-54GV (M579)
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OPERATION MANUAL
NOTE:
In order to see the type and model of the machine, please see the
specication plate. Usually found on the back of the machine. See
example (Fig.1)
Fig.1
TURRET MILLING MACHINE
MACHINE
MODEL NO.
SERIAL NO.
DATE OF MANF.
NOTE:
This manual is only for your reference. Owing to the continuous improvement of the HAFCO
machines, changes may be made at any time without obligation or notice. Please ensure
the local voltage is the same as listed on the specication plate before operating this
electric machine.
Distributed by
www.machineryhouse.co.nz
MACHINE DETAILS
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OPERATION MANUAL
C O N T E N T S:
1. GENERAL MACHINE INFORMATION
1.1 Specications................................................................ 4
1.2 Identication HM-51B............................................... 5
1.3 Identication HM-54GB............................................ 6
2. IMPORTANT INFORMATION
2.1 General Metalworking Safe Practices.................. 7
2.2 Safe Work Practices For Milling Machine............ 10
2.3 Lifting Instructions..................................................... 11
3. SETUP
3.1 Clean Up......................................................................... 12
3.2 Site Preparation........................................................... 12
3.3 Machine Leveling........................................................ 13
3.4 Electrical Installation.................................................. 13
3.5 Full Load Current Rating........................................... 14
4. COMMISSIONING
4.1 Basic Controls............................................................... 14
4.2 Power Feed.................................................................... 17
4.3 Test Run.......................................................................... 18
5. OPERATION
5.1 Table Movements........................................................ 20
5.2 Head Movements........................................................ 21
5.3 Mounting The Tooling............................................... 23
5.4 Horizontal Setup (HM-54GV).................................. 24
5.5 Changing The Spindle Speeds............................... 24
6. MAINTENANCE
6.1 Lubrication Schedule................................................. 28
6.2 Gib Adjustment............................................................ 29
6.3 Troubleshooting.......................................................... 30
SPARE PARTS.......................................................................... 32
Risk Assessment................................................................... 51
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1.1 SPECIFICATIONS
Product Code M577 M579
Model HM-51B HM-54GV
Type Vertical Vertical/Horizontal
Table Size (mm) 1000 x 240 1000 x 240
Spindle Taper Horizontal Nil NT-30
Spindle Taper Vertical NT-30 NT-30
Longitudinal Travel (X-Axis) (mm) 580 600
Cross Travel (Y-Axis) (mm) 190 200
Vertical Travel (Z-Axis) (mm) 350 340
Type of Slides Dovetail Dovetail
Ram Travel (mm) 350 450
Spindle to Table (mm) 390 375
Spindle Travel / Diameter (mm) 125/90 125/90
Throat Depth (max.) (mm) 550 640
Tilting Head (Left ~ Right) ±90 ° ±45 °
Tilting Head (Forward ~ Back) Fixed Fixed
Drilling Capacity (mm) 30 40
End Milling Capacity (mm) 25 25
Face Milling Capacity (mm) 80 80
Power Feed - Quill (mm/rev) Manual Manual
Power Feed - Longitudinal (X-Axis) (mm/min) 20 - 2000 20 - 2000
Power Feed - Cross (Y-Axis) (mm/min) Optional Optional
Power Feed - Vertical (Z-Axis) (mm/min) Optional Optional
Table T-Slot Size (mm) 14 14
Work Table Load Capacity (kg) 175 160
Work Table Swivel (LH/RH) 30 °/40 ° 30 °/40 °
Spindle Speeds Vertical (no/rpm) 9 (220 - 2400) Variable (100 - 2000)
Spindle Speeds Horizontal (no/rpm) Nil 9 (60 - 1350)
Motor Power - Vertical (kW/hp) 2.2 / 3 2.2 / 3
Motor Power - Horizonta (kW/hp) Nil 1.5 / 2
Voltage / Amperage (V/amp) 240/15 240/15
Dimensions (L x W x H) (mm) 138 x 140 x 210 138 x 150 x 215
Shipping Dimensions (L x W x H) (mm) 134 x 114 x 227 134 x 114 x 225
Weight (kg) 850 900
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1.2 IDENTIFICATION HM-51B
B
AHead IBase
BMotor JsplasH tray
CBelt drive cover Kcoolant puMp
DraM L“Z” axis Handle
Edigital readout M“y” axis Handle
FtaBle Nspindle guard
G“x” axis Hand-wHeel Ospindle Fine Feed Hand-wHeel
Hpower Feed unit Pcontrol panel
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OPERATION MANUAL
1.3 IDENTIFICATION HM-54GB
B
AHead IBase
BMotor JsplasH tray
CvariaBle speed selector Kcoolant puMp
DHoriZontal arBor support L“Z” axis Handle
Edigital readout M“y” axis Handle
FtaBle Nspindle guard
G“x” axis Hand-wHeel Ospindle Fine Feed Hand-wHeel
Hpower Feed unit P2 xcontrol panels
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OPERATION MANUAL
DO NOT use this machine unless you have read this manual or have been instructed in the use
of this machine in its safe use and operation
This manual provides safety instructions on the proper setup, operation, maintenance, and
service of this machine. Save this manual, 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 re or
serious personal injury—including amputation, electrocution, or death.
The owner of this machine is solely responsible for its safe use. This responsibility includes, but
is not limited to proper installation in a safe environment, personnel training and authorization
to use, proper inspection and maintenance, manual availability and comprehension, of the
application of the safety devices, integrity, and the use of personal protective equipment.
The manufacturer will not be held liable for injury or property damage from negligence,
improper training, machine modications or misuse.
WARNING
2.1 GENERAL METALWORKING SAFE PRACTICES
Always wear safety glasses or goggles.
Wear appropriate safety footwear.
Wear respiratory protection where required.
Gloves should never be worn while operating the machine, and only worn when
handling the workpiece.
Wear hearing protection in areas > 85 dBA. If you have trouble hearing someone speak
from one metre (three feet) away, the noise level from the machine may be hazardous.
DISSCONNECT THE MACHINE FROM POWER when making adjustments or servicing.
Check and adjust all safety devices before each job.
Ensure that guards are in position and in good working condition before operating.
Ensure that all stationary equipment is anchored securely to the oor.
Ensure all machines have a start/stop button within easy reach of the operator.
Each machine should have only one operator at a time. However, everyone should know
how to stop the machine in an emergency.
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Ensure that keys and adjusting wrenches have been removed from the machine before
turning on the power. Appropriate storage for tooling should be provided.
Ensure that all cutting tools and blades are clean and sharp. They should be able to cut
freely without being forced.
Stop the machine before measuring, cleaning or making any adjustments.
Wait until the machine has stopped to clear cuttings with a vacuum, brush or rake.
Keep hands away from the cutting head and all moving parts.
Avoid awkward operations and hand positions. A sudden slip could cause the hand to
move into the cutting tool or blade.
Return all portable tooling to their proper storage place after use.
Clean all tools after use.
Keep work area clean. Floors should be level and have a non-slip surface.
Use good lighting so that the work piece, cutting blades, and machine controls can be seen
clearly. Position or shade lighting sources so that they do not cause any glare or reections.
Ensure there is enough room around the machine to do the job safely.
Obtain rst aid immediately for all injuries.
Understand that the health and re hazards can vary from material to material. Make sure all
appropriate precautions are taken.
Clean machines and the surrounding area when the operation is nished.
Use proper lock out procedures when servicing or cleaning the machines or power tools.
Do not distract an operator. Horseplay can lead to injuries and should be strictly
prohibited.
Do not wear loose clothing, gloves, necktie’s, rings, bracelets or other jewellery that can
become entangled in moving parts. Conne long hair.
Do not handle cuttings by hand because they are very sharp. Do not free a stalled cutter
without turning the power o rst. Do not clean hands with cutting uids.
Do not use rags near moving parts of machines.
Do not use compressed air to blow debris from machines or to clean dirt from clothes.
DO NOT
×Do not distract an operator. Horseplay can lead to injuries and should be strictly
prohibited.
×Do not wear loose clothing, gloves, necktie’s, rings, bracelets or other jewellery that can
become entangled in moving parts. Conne long hair.
×Do not handle cuttings by hand because they are very sharp. Do not free a stalled cutter
without turning the power o rst. Do not clean hands with cutting uids.
×Do not use rags or wear gloves near moving parts of machines.
×Do not use compressed air to blow debris from machines or to clean dirt from clothes.
×Do not force the machine. It will do the job safer and better at the rate for which it was
designed.
2.1 GENERAL METALWORKING SAFE PRACTICES Cont.
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2.1 GENERAL METALWORKING SAFE PRACTICES Cont.
HAZARDS ASSOCIATED WITH MACHINES include, but are not limited to:
• Being struck by ejected parts of the machinery
• Being struck by material ejected from the machinery
• Contact or entanglement with the machinery
• Contact or entanglement with any material in motion
Health Hazards (other than physical injury caused by moving parts)
• Chemicals hazards that can irritate, burn, or pass through the skin
• Airborne items that can be inhaled, such as oil mist, metal fumes, solvents, and dust
• Heat, noise, and vibration
• Ionizing or non-ionizing radiation (X-ray, lasers, etc.)
• Biological contamination and waste
• Soft tissue injuries (for example, to the hands, arms, shoulders, back, or neck) result
ing from repetitive motion, awkward posture, extended lifting, and pressure grip)
Other Hazards
• Slips and falls from and around machinery during maintenance
• Unstable equipment that is not secured against falling over
• Safe access to/from machines (access, egress)
• Fire or explosion
• Pressure injection injuries from the release of uids and gases under high pressure
• Electrical Hazards, such as electrocution from faulty or ungrounded electrical
components
• Environment in which the machine is used (in a machine shop, or in a work site)
Machines are safeguarded to protect the operator from injury or death with the placement of
guards. Machines must not be operated with the guards removed or damaged.
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2.2 SAFE WORK PRACTICES FOR MILLING MACHINE
DO NOT use this machine unless you have been instructed in its safe use and operation
and have read and understand this manual
Safety glasses must
be worn at all times
in work areas.
Long and loose hair
must be contained.
Gloves must not be
worn when using this
machine
Sturdy footwear
must be worn at all
times in work areas
Close tting/protec-
tive clothing must be
worn.
Rings and jewellery
must not be worn.
PRE-OPERATIONAL SAFETY CHECKS
qLocate and ensure you are familiar with all machine operations and controls.
qEnsure all guards are tted, secure and functional. Do not operate if guards are
missing or faulty.
qCheck workspaces and walkways to ensure no slip/trip hazards are present.
qEnsure cutter is in good condition and securely mounted.
qCheck coolant delivery system to allow for sucient ow of coolant.
OPERATIONAL SAFETY CHECKS
qKeep clear of moving machine parts.
qFollow correct clamping procedures. Keep overhangs as small as possible and check
the workpiece is secure.
qSet the correct speed to suit the material, cutter diameter, the depth of cut
ENDING OPERATIONS AND CLEANING UP
qSwitch o the machine when work completed.
qRemove milling cutters and store them safely.
qBefore making adjustments and measurements or cleaning swarf accumulations,
Switch o and bring the machine to a complete standstill.
qLeave the machine and work area in a safe, clean and tidy state.
POTENTIAL HAZARDS AND INJURIES
qSharp cutters. q Hair/clothing caught in moving parts. qEye injuries.
qSkin irritation. qMetal splinters and burrs. qFlying debris.
DON’T
qDo not use faulty equipment. Immediately report suspect machinery.
qNever leave the machine running unattended.
qDo not leave equipment on top of the machine.
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