XLO Ex-Cell-O 602 User manual

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Foreword
Index
In orcler that this milling -`chine may give con-
tinuous, satisfactory service, it ls necessary that it be
properly installed, opcratcd and maintained. This
manual is printed with this in view. It should be
placc.d in the hands of the proper supervisor in the
plant and the information it contains should be
studied carefully.
This milling machine was designed and manufac-
tured to conform to Ex-Cell-O's high standard of
machine tool pcrformancc.. It was built to rigid speci-
fications by trained workmen, under competent
supervision. It was inspcctcd at various stages of
construction. and has been tested in actual operation.
Some details of the. machine furnished may differ
from the description in this book. The reason for
such difference is constant improvement in design)
equipment and matcrjals, as well as changes neces-
sary to fill individual orders.
Installation
Lubric.ation
Operating Instructions
Scrvicc Information
Ordering Instructions
Operating Temperature
Vibration
Adjusting Gibs
Spindle Brake & Lock Adj.
Removing Vari-Speed Cover
Spindle Belt Replacement
Replacing C)uill Return Spring
Removing Spindle Quill Sub Assembly &
Replacing Quill Guard
Lead Screw Back Lash Adj.
Machine Specifications
Mac.hine Ass'y Dwg. & Stock List
Back Lash Eliminator Dwg. & Stock List
(Optional)
l5
9
10
15
Spring Loaded Table Handwheels (Optional) 15
Head Ass'y Dwg. & Stock List
Right Angle Attachment (Optional)
Table Power Feed Ass'y Dwg. & Stoc.k
List (Optional)
O.P.L. Optical Measurinc! Attachment
(Optional)
D.O.M. Direct Reading Optical Measuring
Attachment (Optional)
EILj=

Installation
EX-CELL-0 RAM TURRET
MILLING MACHINE - STYLE 602
preparing Machine for Installation:
when machine ls uncrated, check all parts and
acccssorles a_-nst the packlng list to make sure
nothing is missing.
The following items arc shipped With the maChlne.
shipping list, instructions, operation and mainten-
ance bulletin. electrical scrvicc. information.
After the machine ls uncratC,d. it nluSt be inSPCCtCd
to ascertain thi\t no part has been damaged or dis-
arranged during shipment. All the paper wrappings
that have bcc.n used to prc\,ent dust and dirt from
gettmg into the machine should be removed The
wooden skids must bc. left ()n the machine until it is
placed in position.
The machinc. should bc placed in the deSirl.d loca-
tion with sufflclent room between surrounding ma-
chines to allow efficient operation. When a crane is
used to lift the machine mto position. the lifting
sling should be placed around the front of the ram.
LIFTING SLING
I_-__--
-
Ei=
F=ILeL-
7Tr` proEct Bottom
1 and Sides of I(am
_` . MoveTable to Rear
?ng;h\,_±=
caution must bc exercised especially during the
instalkttion of the machine. No force should be
exerted on the spindle since the closely fitted pre-
cision ball bearing races COuld be damaged.
Install Table Dials and Handwheels:
on some models, table dials and handwheels are
sl"ppcd m the rear compartment of the mlll. Place
dials on table lead screw. screw handwtlccl on lead
screw until it is _oo5 from dial. Screw jam nut on
lead screw and lock against handWheel. Check dial
anc] handwheel clearance with.()()5 fcelcr. Adjust if
necessary
Foundatiol1:
To get satisfactory PCrfOrmanCe, it iS important
that the "lchin|. has a solid foundation and that it
is lcvcI. A solld concrete floor or foundation gives
the bc.st footim|. but a firm wooden floor, free from
vltmtion -y bc used. when the machine is placed
on an upper floor ()r balcony. it should be as close
as possible to a pillar or colunln.
Leveling:
Four foundation rest pads and bolt hOIC.S arc Pro-
vided at the bottom of the base of the machine.
stc.el wcdees. n|.vcr wooden wedges should be used
under the rest pads for lcvcling. The level should be
pk\ced lengthwisc and crosswise on the table. A
good machinist,s lcvcl should be used. and the bubble
should bc allowed sufficient time to come to rc.st.

Lubrication
EX-CELL-a RAM TuRRET
MILLING MACHINE - STYLE 602
The machine must be lubricated before it lS
started. The use of the proper lubricant at the desig-
mlted places ls necessary to obtaln the best OPerating
pcrformancc and to insure the maxlmum service
llfc of the machine.
Back Gear Housing Oll Level should be checked
periodically zlnd an oil such as #30 S.A.E. is recom-
mended. The housing should be filled to oil level
line on window.
The Oil Cup and Oil Fittings Should bC filled
with a way oll daily.
The grcasc flttingS Should bC greased Weekly.
splndlc Bearings :Ire lubricated and sealed for the
life of the machine.
MOTORS - The manufacturcr`s recommendation
should bc followed.
when the machine is equipped with optional table
power feed, the oil level in the gear box should be
checked periodically and filled until it flows out the
fiIImg hole, with #30 SAE.
on machine equipped with optional one shot
lubrication system. use socony-Mobil Oil Vactra #2
or equivalent.
Discretion in oiling and greasing Should be em-
ployed at all times. Over oillng and greasing may
result in an undesirable escape of these substances
from the mac.hine. If this trouble is experienced Cut
down on amount of lubricant used or increase
period of applicatlon accordingly.

Operating
Instructions
EX-CELL-0 RAM TURRET
MILLING MACHINE - STYLE 602
A. Spindle Start-Stop-Reverse
Lot.ated on left side of head and is used to obtain
clockwise and counter clockwlSC rotation Of SPindle.
B. Spindle Brake & Lock:
Applied by nlOVln= lCVC.r l)n left Side Of belt housing.
To lock splndlL. \+,`hen Chim_Cln_I tools. move lcvcr to
the horl7.ant:ll POSItiOn. CA(/7_/()A/. The motor can
hc da-ll=cd lf lt lS turned On While thl. brake Icvcr
is in the horiz"1tnI (lot.k ) posltlom
C. Spindle Speed Selector:
('AU7/OIV.. DiallnL= SPindlC SPCCd must bC PCr-
formcd only while motor is runnim!. lnflnitC SPindlC
spccd is ()btaincd by dlllling SPCCII :I.lector clockwise
for faster speeds. ilnd countL.r Cl()I.k\\iSl. for Slower
sr)cods. :lnd rc:tdil|r dl.sirc.d sllindlL. SPCCd On the dl-
rcct rc:\dln_i! sr)cl.I diill- ln llieh ranlL!C.. any SPCCd
fron1 620 R P.M. to 3800 R Pl.M may be sclcctcd
aml in low ramte an_\, sr)cod from loo to 640 R P-M-
D. Spindle Speed Dial:
Actual spindle speed IS indicated in RPM. Rcild
spindle R-P M opposite r:ml±l. in which machine is
opcratil|e-
E. High.Low Spindle R.P.M. Selector Lever:
CA I/7-/OIV. M()t()r must be st()pr)cd before cn_a.1ging
or dlsenJea-t!lnLL! Sell,ctor lever- To position lcvcr.
rotate motor slll.il\.a by h:md until Cneaeement iS
made
F. Quill Lock:
Thc. quill may bc lockc(I in :\ny posltIOn by rotating
the lock lc`vcr |`loc.kwls|`
a. Quill Hand Lever:
Adjustc.d to 8 opl.rlltln!! positions by lnOVlng Out-
wards on levl.r hub :m(I tllrnim: to desirc.cl position-
H. Power Feed Selector:
Feeds of.00I5,.()()3 or.0()6 inchl,s per revolution of
splndll. may be selec.ted bv turnlne leVl.I tO the
dc.slrl.d fl.ed Sl"In|r. A nl.urral positron lS Provided
bctwl.I.n a:\cll feed SCltinC When power fcc.d is not
requlrcd. Sell.I,tor should`be ln the neutral position.
Fcl.d selections arc. m()rl. a.:\sily malll. when spindle
is runIling- CAUTION. Fl.I.d Sl,lCCtOr Should not bC
turned whl,n qulll iS llndl.r load. DISC.n|L!ilgC Power
fc.|.d c.lulch flrst.

J. Fine Feed Hand Wheel:
Operated by turning power feed selector to neutral
position and engaging power feed clutch.
I(. Power Feed Clutch Knob:
(NOTE: Clutch knob has a left hand thread.) power
feed lo quill is engaged by turning clutch knob
counter clot.kwise. VI/hen light feeding forces are
required, the knob can be tightened easily by grasp-
ing it directly. When higher thrust, up to the limit of
the head are required, the tightening is effected
easier by sliding the hand feed lever to the right so
that it engages the fccd knob in one of 8 pos;lions.
The greater the force applied to the lever - the
proportionally _greater feeding force is applied to the
quill.
L. Power Feed Reversing Knob:
Located in the center of the fime feed handwheel.
Pull knob out to feed down, push in to feed up,
M. Quill Stop & Micrometer Nut:
Depths may be contrc)Iled by setting micrometer nut
in conjunction with quill stop. Each graduation on
nut indicates one thousand of depth.
N. Draw Bar:
When tightening or loosening the draw bar. use
spindle brake to lock spindle.
P. Angular Setting of Head:-Rotating with Table:
Loosen five locl(ing screws "O" and adjust head to
clesired setting by turning shaft "p" from either side
of ram with crank handle.
R. Angular Setting of Head-Swinging Across Table:
Loosen six screws "a" three on each side of head.
Adjust head to desired setting by turning shaft 'R.,
with crank handle.
T: Positioning of F]am:
To acljust ram. loosen two lock nuts {.s" and adjust
ram in or out by rotating stlaft "I with cramk
handle. Care should be taken to retighten locking
nuts "S".
U. Turret Rotation:
To rotate turret, loosen four screws "u,,, rotate ram
and turret amd tighten screws.
V. Rotation of Upper Portion of Head:
This could be an advantage when head js tilted into
various positions to give greater clearance for the

OPERATING INSTRUCTIONS:
dnvc or to positlon the controls in a more accessible
position.
Thls JOlnt Occurs betWCCn the quill houslng and gear
housing. Loosen four screws "V'' in the top flange of
the quill housinLq (Body) and rot.1tC the top POrtiOn
of head to desired position- RctiLJlten the four
Screw.S
W. Table Clamp:
X. Cross-Slide Clamp:
Y. I(nee Clamp:
NOTE: The table. cross slide amd knee Should be
clamped when not being used to insure a rigid set up.
Z. Gin Adjusting Screws:
Head Alignment for Precision and other accurate
Machining:
Place dial indicator in spindle nose.
Loosen 5 clamp screws "O'' and rotate head by
worm shaft..p". |mtll idcntlcal readings are ot)tained
on th|. indicator at "W" and "X". Tiehtcn clamp
screws and chc|.k lndiCiltOr rC.adinr.
- --:_-i___
I_oosen (6) clamp screws ',O'' and rotate head by
worm sllaft "R,. untll identical readim!s are obtained
at.,y" and.,z". Table can be made up to.0005 in.
per ft. hiLll at front. TIL|1tCn Clamp Screws and
check Indicator rcadines,
Service
Instructions
ordering Instructions:
when ordering replacement parts the following in-
formation should bc forwardcd.
1. Part Number and Assembly Number
2. Name of Part
3_ Ouantitv
4. Serial riumber of Machine
To order a replacement not found ln any Of the
following lists; a comr)lctc description. and lf ncces-
sar\, a skletch. should be forwarded with quantity and
serial number of machirle.
operating Temperature of Head:
when the spindll. runs near its top spccd for COn-
tinuous pl.riods of time the tempcraturc of the gear
pot and top bczlring rlnL± Can re:lCh l80''F. with no
aclverse effect ()n the milling nlaChinC-
Vibration:
Th|. natural frcqucncy of the nlillinLg machine iS aP-
r)roxi-tcly I200 C-P.M. If cxccssivc vibration
exists at tIliS SPindlC RPM, adjust RPM slightly.
Adjusting Gills:
Full ll.ngth taperl.d.ribs :\rc used on thc. dovetails of
tllC Style 6()2 Millin_= Machine. Adjust gibs by turn-
ing adjusting screws until a slight drag is felt
when turning the handwhccl. Adjusting screws arc
located in the follow,in± locations: :\t the richt hand
end of the cross slide,iront of cross sllde|hrOugh
clear:mcc holc. in way wiper and on the right hand
cornc.I of kncc`.
Spindle Brake and Lock Adjustment:
Ref. See. "JJ", Page 22
I Rcmo\c Cam Screw 52-I2584 and Brake
Cam 52-l2582.
2(a) Rotate brake lock stud 52-1I888 1/2 turn
clockwise to increase brake pressure.
(b). Rot:\tc. antI-CIockwlsc I/2 turn if brake Shoe iS
dragging.
3. Assc.mbl|` brake c{1m and Cam Screw.
4. ChL.Ck br:\kC. Rcpcat abo\,a if additioIlal ad-
iustmcnt is required.
Removing Vari-Speed Cover:
lief. Sec. "cc", page |6 and See, "ff", page 22
I Rcmovc Covc.I 52-I2005 from top of hcild.
2(a). 2 H.P. Head. Not necessary to nlovc motor.
(b). ll/2 Head. Unbolt motor and place I" board
und|.I. front of motor.
3. Loosen set screws Dc.I. 62 and push fork
hinge pm Dot. 9l from fork.
4. lift fork 52-l2164 and top vari-speed pulley
:\bout I,.. Fork should now bc disengaged from nut
52-l2069.
5. Remove 4 screws Dot. 50 zmd remove front
cot,cr 52-l2014 from head.
6, Check to see that pin Dot. 97 is in slot of
lcvcr 52-l2063.

7. If lever arm is bent slightly it is easier to bend
back than replace lever.
8 The linkage should move freely with no
binding.
Assembling
Reverse of above.
Move motor towards rear of machine when
ti_=1ltening bolts.
Spindle Belt Replacement:
Ref. page 16 and page 22
METHOD J=1:.- Without tool for removing spring
cartridge from motor pulley:
1. Adjust spindle spec.d to loo RPM.
2. Remove cover 52-l2UU5 from top of head.
3. With motor off. adjust spindle speed setting to
22OO RPM.
4. Remove four 3/8 Hex. Hd. Scr. from motor
flange & place r board under front of motor.
5. Loosen set sc.rows Det. 62 and push fork hinge
pins Dot. 9l from fork.
6. Lift fork 52-l2164, gimbal rings 52-12162 &
52-l2163 and top half of spindle pulley 52-12008 up
until pulley hits bottom of motor flange.
7. Lift fork and remove from head.
8. Remove drum switch from side of belt housing
(do not disconnect wires)
9. With aid of crane or additional man lift motor
and top half of spindle pulley up until spindle pulley
is off shaft. Note: Guide belt through opening in
belt housing.
lO. Turn motor on its side and place on belt hous-
ing.
I I. Wedge a piece of wood between the two halves
of the spring loaded motor pulley.
l2. Remove old belt from motor pulley.
Installation:
1. Place new belt around motor pulley.
2. Hold belt around pulley so that it does not
slip out and remove wedge.
3. Lift nlOtOr and Place end Of belt Over spindle
splines, assemble top halt of spindle pulley. Guide
belt through opening in belt housing and mount
"notor. Move motor towards rear of belt housing
as far as possible before tightening screws.
4. Lift top half of spindle pulley until it tout;hes
motor and assemble fork with glmbal ring and nut
52-12169. Replace fork hinge pins and tighten set
.Screws.
5. Replace drum switch.
6. Adjust spindle speed with motor off, until top
half of spindle pulley lightly contacts belt.
7. Start motor and check that fork is working pro-
perly when spindle speed is adjusted.
8. Replace top cover.
METHOD #2: With tool TL-5512 for removing
spring cartrldge from motor pulley.
1. Adjust head speed to 2400 RPM.
2. Using 7/l6 socket remove grease fitting in end
of spring cartridge.
3. Insert shaft of clamp tool and tighten handle
until spring pressure js off retaining ring. Remove
retaining ring. Loosen clamp.
4. Remove clamp and stud.
5. Remove 4, 3/8" hex hd. SCr,S. from motor flange.
Hold vari speed cartridge. Move motor to center of
opening in varl speed housing and remove cartridge.
6. Remove motor.
7. Remove cover 52-l2005.
8. Remove two pins Detail 9l which vari speed
fork 52-I 2164 piyots on. Lift out fork, sliding gimbal
ring and top half of spindle pulley 52-l2008 up and
off. Some servicemen find it more convenient to
remove front cover 52-l2014 at same time as re-
moving fork.
lmstructions for Replacing Quill Return Spring:
Ref. See. "ee", page 22 and page l7
I. Place piece of wood on table and position table
so there is approximately 6l/2 inches between end Of
spindle and board.
2. Loosen set screw Det. l24 holding top of stop
screw No. 52-ll873. Unscrew stop screw approxi-
mately 5 inches. Remove stop block 52-ll872 by
removing Soc. Hd. Scr. Det. l25.
3. Move quill down approximately 5 inches.
4. Place scriber in hole in guard located in quill
stop slot in body. Lift up and move to the left I inch.
5. Securely hold end of quill and feed quill down
by hand feed lever until feed gear disengages quill
rack.
6. Hold quill in this position while the spring ten-
sion on hand feed lever is released by turning lever
back. (no tension when spring is broken).
7. Remove set screw Det. l28 and unscrew worm
No. 52-l2O38.
8. Remove head flange worm gear No. 52-l1876.
Two holes are tapped for 7/16-l4 screw to jack
worm gear out.
9. Remove spring retaining nut No. 52-l2186.
10. Remove broken spring No. 52-11984 on hub
No. 52-12187.
ll. CAUTION: If spring 52-11984 is not broken a
spring retainer must be used when removing spring.
Tighten spring tension by turning hand feed lever
clockwise until O.D. of spring is 2.75 inches. Slip
2.8 I.D. retainer around spring. Slowly release feed
handle.

Installing:
I. Insert new spring) hub and retaining ring in
head, attaching end of spring over pin Det. 89. In-
stall spring retaining nut.
2. Tighten up spring tension by turning hand feed
lever clockwise so that retaining ring can be removed
from O.D. of spring. Slowly unwind hand feed lever.
3. While holding quill apply spring tension by turn-
ing hand feed lever clockwise approximately 4 turns,
push quill up until quill rack engages feed gear.
4. Replace stop block-
5. Position quill until approximately 5 inches is
extended from body.
6. C)uill guard must be positioned by inserting
scriber in small hole and rotating guard to right until
scriber touches right side of slot in body. If guard is
correctly located the quill will enter guard when the
quard is held down by the scriber and the quill is
retracted. Slowly move quill up and down its full
stroke. Do not force as the guard's tab is easily
broken.
7. Posltlon stop screw and tighten Det. l24.
Removing Spindle-Quill Sub Assembly and
Replacing Quill Guard:
Ref. page 16 and page 22
REMOVING :
I. Loosen set crew Det. l24, llOlding top Of Stop
screw No. 52-I 1873. Unscrew stop screw approxi-
mately 5 inches. Remove stop block 52-11872 by
removing Soc. Hd. Scr. Det. l25.
2. Move quill down approximately 5 Inches.
3. Place scriber in hole in guard. Lift up and move
to the left 1 inch.
4. Holding bottom of quill to er\sure it does not
fall, wind quill down approximately 4 turns and it
will disengage the pinion from the rack. The full
weight of the quill will be taken by left hand (approx.
30 lbs.). Allow the hand feed lever to unwind. Slowly
release the spring tension.
5. Remove quill from body.
6. Remove guard by pulling down through body.
INSTALLING :
1. Insert new guard with tab towards bottom and
small hole in line with slot in body.
2. Insert quill in I)ody, approximately 5 inches,
lining spindle splines with drive sleeves by rotating
spindle.
3. While holding quill apply SPring tension by
tuming hand feed lever clockwise approximately 4
tums, push quill up until quill rack engages feed
gear.
4. Replace stop block.
5. Pclsition quill until approximately 5 inches is ex-
tended from body.
6. Quill guard must be positioned by inserting
scriber in small hole and rotating quard to right until
scriber touches right side of slot in body. If guard js
c.orrectly located the quill will enter guard when the
guard is held down by the scriber and the quill is
retracted. Slowly move quill up and down its full
stroke. Do not force as the guard's tab is easily
broken.
7. Position stop screw and tighten Det. 124.
Adjusting Optional
Lead S¢rew Back Lash Eliminator
See page 15
Gin Adjustment:
UNLOCK GIB.
Loosen outer sc.lew by turning Clockwise.
TIGHTEN GIB.
Pass key through outer screw and into inner Screw.
Tighten screws by rotating clockwise until a slight
drag is felt when rotating handwheeI.
LOOSEN GIB.
Turn screws anti-clockwise,
LOCK GIB.
Turn outer scrl.w zlnti-I.lockwisc against gib lug.