Operating Instructions and Parts Manual Table Powerfeed Models: TPFA-2X / TPFA-2XN / TPFA-2Y / TPFA-2YN / TPFA-2Z

Transcription

1 This Manual is Bookmarked Operating Instructions and Parts Manual Table Powerfeed Models: TPFA-2X / TPFA-2XN / TPFA-2Y / TPFA-2YN / TPFA-2Z WMH TOOL GROUP, Inc Vantage Drive Elgin, Illinois Part No. M Ph.: Revision B 7/07 Copyright 2007 WMH Tool Group

2 Warranty and Service WMH Tool Group, Inc., warrants every product it sells. If one of our tools needs service or repair, one of our Authorized Service Centers located throughout the United States can give you quick service. In most cases, any of these WMH Tool Group Authorized Service Centers can authorize warranty repair, assist you in obtaining parts, or perform routine maintenance and major repair on your POWERMATIC tools. For the name of an Authorized Service Center in your area call MORE INFORMATION WMH Tool Group is consistently adding new products to the line. For complete, up-to-date product information, check with your local WMH Tool Group distributor, or visit powermatic.com. WARRANTY POWERMATIC products carry a limited warranty which varies in duration based upon the product. WHAT IS COVERED? This warranty covers any defects in workmanship or materials subject to the exceptions stated below. Cutting tools, abrasives and other consumables are excluded from warranty coverage. WHO IS COVERED? This warranty covers only the initial purchaser of the product. WHAT IS THE PERIOD OF COVERAGE? The general POWERMATIC warranty lasts for the time period specified in the product literature of each product. WHAT IS NOT COVERED? The Five Year Warranty does not cover products used for commercial, industrial or educational purposes. Products with a Five Year Warranty that are used for commercial, industrial or education purposes revert to a One Year Warranty. This warranty does not cover defects due directly or indirectly to misuse, abuse, negligence or accidents, normal wear-and-tear, improper repair or alterations, or lack of maintenance. HOW TO GET SERVICE The product or part must be returned for examination, postage prepaid, to a location designated by us. For the name of the location nearest you, please call You must provide proof of initial purchase date and an explanation of the complaint must accompany the merchandise. If our inspection discloses a defect, we will repair or replace the product, or refund the purchase price, at our option. We will return the repaired product or replacement at our expense unless it is determined by us that there is no defect, or that the defect resulted from causes not within the scope of our warranty in which case we will, at your direction, dispose of or return the product. In the event you choose to have the product returned, you will be responsible for the handling and shipping costs of the return. HOW STATE LAW APPLIES This warranty gives you specific legal rights; you may also have other rights which vary from state to state. LIMITATIONS ON THIS WARRANTY WMH TOOL GROUP LIMITS ALL IMPLIED WARRANTIES TO THE PERIOD OF THE LIMITED WARRANTY FOR EACH PRODUCT. EXCEPT AS STATED HEREIN, ANY IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS ARE EXCLUDED. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG THE IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. WMH TOOL GROUP SHALL IN NO EVENT BE LIABLE FOR DEATH, INJURIES TO PERSONS OR PROPERTY, OR FOR INCIDENTAL, CONTINGENT, SPECIAL, OR CONSEQUENTIAL DAMAGES ARISING FROM THE USE OF OUR PRODUCTS. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU. WMH Tool Group sells through distributors only. The specifications in WMH catalogs are given as general information and are not binding. Members of WMH Tool Group reserve the right to effect at any time, without prior notice, those alterations to parts, fittings, and accessory equipment which they may deem necessary for any reason whatsoever. 2

3 Table of Contents Warranty and Service...2 Table of Contents...3 Introduction...6 Specifications...6 Unpacking...6 Shipping Contents...7 Contents of the Box...7 X AXIS Installation and Features...8 Installation...9 TPFA-2X/TPFA-2XN Installation...9 TPFA-2Y/TPFA-2YN Installation...10 TPFA-2Z Installation...10 TPFA-2Z (Knee-Lift) Installation...11 Troubleshooting...12 Replacement Parts...12 Parts Breakdown (All Models)...13 Parts List (All Models)...14 Electrical Connections

4 Warning 1. Read and understand the entire owner's manual before attempting assembly or operation. 2. Read and understand the warnings posted on the machine and in this manual. Failure to comply with all of these warnings may cause serious injury. 3. Replace the warning labels if they become obscured or removed. 4. This powerfeed is designed and intended for use by properly trained and experienced personnel only. If you are not familiar with the proper and safe operation of a powerfeed and/or milling machine, do not use until proper training and knowledge have been obtained. 5. Do not use this powerfeed for other than its intended use. If used for other purposes, WMH Tool Group disclaims any real or implied warranty and holds itself harmless from any injury that may result from that use. 6. Always wear approved safety glasses/face shields while using a milling machine. Everyday eyeglasses only have impact resistant lenses; they are not safety glasses. 7. Before operating machinery, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair. Non-slip footwear or anti-skid floor strips are recommended. Do not wear gloves. 8. Wear ear protectors (plugs or muffs) during extended periods of operation. 9. Some dust created by power sanding, sawing, grinding, drilling and other construction activities contain chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are: Lead from lead based paint. Crystalline silica from bricks, cement and other masonry products. Arsenic and chromium from chemically treated lumber. Your risk of exposure varies, depending on how often you do this type of work. To reduce your exposure to these chemicals, work in a well-ventilated area and work with approved safety equipment, such as face or dust masks that are specifically designed to filter out microscopic particles. 10. Do not operate this machine while tired or under the influence of drugs, alcohol or any medication. 11. Make certain the switch is in the OFF position before connecting the machine to the power supply. 12. Make certain the machine is properly grounded. 13. Make all machine adjustments or maintenance with the machine unplugged from the power source. 14. Remove adjusting keys and wrenches. Form a habit of checking to see that keys and adjusting wrenches are removed from the machine before turning it on. 15. Keep safety guards in place at all times when the machine is in use. If removed for maintenance purposes, use extreme caution and replace the guards immediately. 16. Check damaged parts. Before further use of the machine, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced. 17. Provide for adequate space surrounding work area and non-glare, overhead lighting. 18. Keep the floor around the machine clean and free of scrap material, oil and grease. 19. Keep visitors a safe distance from the work area. Keep children away. 20. Make your workshop child proof with padlocks, master switches or by removing starter keys. 4

5 21. Give your work undivided attention. Looking around, carrying on a conversation and horse-play are careless acts that can result in serious injury. 22. Maintain a balanced stance at all times so that you do not fall or lean against moving parts. Do not overreach or use excessive force to perform any machine operation. 23. Use the right tool at the correct speed and feed rate. Do not force a tool or attachment to do a job for which it was not designed. The right tool will do the job better and safer. 24. Use recommended accessories; improper accessories may be hazardous. 25. Maintain tools with care. Keep cutting tools sharp and clean for the best and safest performance. Follow instructions for lubricating and changing accessories. 26. Make sure the workpiece is securely attached or clamped to the table. Never use your hand to hold the work piece. 27. Turn off the machine and disconnect from power before cleaning. Use a brush or compressed air to remove chips or debris do not use your hands. 28. Do not stand on the machine. Serious injury could occur if the machine tips over. 29. Never leave the machine running unattended. Turn the power off and do not leave the machine until it comes to a complete stop. 30. Remove loose items and unnecessary work pieces from the area before starting the machine. Familiarize yourself with the following safety notices used in this manual: This means that if precautions are not heeded, it may result in minor injury and/or possible machine damage. even death. This means that if precautions are not heeded, it may result in serious injury or possibly - - SAVE THESE INSTRUCTIONS - - 5

6 Introduction This manual is provided by WMH Tool Group, Inc. and contains installation instructions, safety precautions and parts breakdown for the TPFA Series Table Powerfeed. If there are any questions or comments, please contact either your local supplier or WMH Tool Group. WMH Tool Group can also be reached at our web site: Specifications Model Number... TPFA-2X... TPFA-2Y Stock Number Table Movement... X-axis (longitudinal)...y-axis (crossfeed) Maximum Torque (in./lbs.) Model Number... TPFA-2XN...TPFA-2YN... TPFA-2Z Stock Number Table Movement... X-axis (longitudinal)...y-axis (crossfeed)... Z-axis Maximum Torque (in./lbs.) All Models Motor A, 1Ph, 110V, 50/60Hz Variable Speed Range (in./min.) Rapid Traverse Speed (in./min.) Net Weight (lbs.) The above specifications were current at the time this manual was published, but because of our policy of continuous improvement, WMH Tool Group, Inc. reserves the right to change specifications at any time and without prior notice, without incurring obligations. Unpacking Inspect the contents of the box and check for shipping damage. Report any damage immediately to your distributor and shipping agent. Do not discard any shipping material until the Powerfeed is assembled and running properly. Compare the contents of your container with the following parts list to make sure all parts are intact. Missing parts, if any, should be reported to your distributor. Some parts have been given a protective coating. Remove this using a soft cloth and a cleaner degreaser. 6

7 Shipping Contents Contents of the Box A Powerfeed with attached limit switch B Bevel gear with dial nut C Socket head cap screws G Set of small shims F Set of large shims E Cable ties D Cable clamps, w/ screws and washers H Travel stops J Crank handle K Adaptor L Washer with keyway M Bushing N Bushing P Nut R Spacer S Plate w/fasteners T Roll pin U T-way track pieces w/ fasteners V Connector base W Limit switch mounting bracket w/ screws X Spring Y Clutch Z Extension shaft AA Key BB Screw and washers for Ext. shaft CC Extension shaft Operator s manual Warranty card Accessories TPFA-2X/2XN Accessories TPFA-2Y/2YN Contents All Models Accessories TPFA-2Z 7

8 X AXIS Installation and Features Figure 1 Read and understand the entire contents of this manual before attempting set-up or operation! Failure to comply may cause serious injury. 8

9 Installation TPFA-2X/TPFA-2XN Installation Referring to Figure 1: 1. Move the table to the extreme left-hand position. 2. Remove jam nut, hand crank, dial nut, dial, dial holder, bearing retainer ring, bearing flange, etc. 3. Slide the bushing onto the lead screw. 4. Slide the adaptor onto the bushing. 5. Secure the adaptor to the end of the table with the existing socket head cap screws. 6. Slide the powerfeed onto the bushing. 7. Secure the powerfeed to the adaptor using the two socket head cap screws provided. Installing Bevel Gear 8. Remove the protective cap from the bevel gear, and slide the bevel gear onto the lead screw. Manually press and turn the bevel gear against the drive gear to check for backlash, and make sure they mesh snugly. Leave the clearance between the two gears as small as possible. If there is some clearance left, place small shims one by one between bearing and bevel gear until the gears are properly fitted. Pack the gears with grease before proceeding. Installing Dial and Hand Crank 9. After proper gear clearance has been set, slide the dial into position to obtain spacing between the dial and the face of the powerfeed (this will prevent chips from entering the gear train.) Use the two solid and two laminated large shims provided to accomplish the spacing. Use further shims if needed. 10. Install the dial nut. Place key in shaft and mount the hand crank. Add the washer and the locking nut, and tighten the locking nut. Installing Limit Switch 11. Remove the standard travel stops from your machine. Install the travel stops provided with your powerfeed unit. It is important that these stops be firmly secured in the table track to prevent them from sliding loose and causing your table to travel too far and possibly damage other parts of the machine. It is recommended that you either place the standard stops back in position to block the new travel stops from sliding; or drill a hole 9 behind the table edge and insert a screw through the travel stops from behind. 12. Loosen and remove the two socket head cap screws holding the T-shaped table stop bracket. NOTE: Retain this original bracket should manual table movement ever be needed again. 13. Place the limit switch over the holes and secure with two 3/8 x 1 socket head cap screws provided. See Figure 2. If the actuators are not symmetrical, grind them to obtain the proper position. 14. Secure the limit switch cord using the provided clamp. Attach it to the right-hand side of the chip scraper with the screw provided. See Figure 2. Figure 2 Never change the direction of power feed movement while the machine is operating, or damage to the gear may result. Turn direction control handle to OFF position and wait for machine to come to a complete stop before reversing direction. IMPORTANT: Installing more than one powerfeed on your machine may reduce table travel. For example, the track assembly for the Y-Axis powerfeed will prohibit full travel of the longitudinal table on which the X-Axis powerfeed is installed. These considerations should be carefully made before installing multiple powerfeeds.

10 TPFA-2Y/TPFA-2YN Installation To Install The Y-Axis Track: Drill and tap #10-24 holes in the right side of the machine base below the table for mounting the T-Way Track. See Figure 3. Note: The limit switch mounting bracket provided with your powerfeed is designed for most mounting situations. However, the casting design of your particular machine may require modifications to the bracket system. Figure 3 To install the Y-Axis Powerfeed unit: Figure 4 shows the installation of the Y-Axis powerfeed. These instructions are similar (with the exception of the adaptor) to those on page 9, steps 1 through 10. Before drilling and inserting the roll pin, make sure all previous steps have been done carefully and correctly. Figure 4 TPFA-2Z Installation To install the Z-Axis Track: Figure 5 10

11 TPFA-2Z (Knee-Lift) Installation To install the Z-Axis Powerfeed unit: 1. Remove hand crank, clutch insert, dial, dial nut, dial holder and bearing flange. 2. Install extension shaft by screwing it onto the table elevating shaft. Important: Shaft end must be against inner ring of bearing. Inner shaft is 16 or 18 threaded UNC. 3. Tighten base to flange then install powerfeed and tighten it on the flange. 4. Remove protective cover from bevel gear and install bevel gear. (Note: Do not install the key yet.) Push and turn the bevel gear by hand to check for backlash. If necessary, add a few shims to obtain proper mesh with the drive gear of the powerfeed unit. Pack bevel gear with grease. Do not use silicon-type grease. Replace gear then push and turn to check again for backlash. 5. Remove the bevel gear. Install key, replace gear, install dial and tighten dial nut. Add a few shims if the dial is grinding the gear. Important: Pack with grease before installing the bevel gear. 6. Install clutch against bevel gear. Drill through one hole of 5mm diameter, and drive the roll pin into the hole. Important: Be sure you have followed each step carefully and correctly before drilling and installing the roll pin. Temporarily install the hand crank and rotate in clockwise direction to check for proper shimming and to make sure there is no binding action. Make any needed adjustments before installing roll pin. 7. Install the spring and hand crank, and rotate again to check for proper shimming and smooth movement. Lubricate the opening in the hand crank for smooth movement on the shaft. Then tighten washer and screw at the end of the shaft. Figure 6 11

12 Troubleshooting Trouble Probable Cause Remedy Powerfeed will not work; power indicator is not lit. Powerfeed will not work, but power indicator is lit. Speed control erratic, or unit only operates at high speed. Breaker keeps tripping during normal operation. Unit will move in only one direction. The limit switch will not stop the table from traveling farther even after contacting the travel stop. No incoming power. Powerfeed switch is off. Circuit breaker on powerfeed has been tripped. Carbon brush is not making proper contact with the armature, or is worn. Internal wiring to the printed circuit board is not properly connected. Potentiometer connections are loose, or potentiometer is faulty. Rapid micro switch is stuck, or its position is too high up. Loose connections or faulty elements. Unit has short circuit. Limit switch malfunctioning. Limit switch not operating correctly. Check plugs connection. Turn switch to ON position. Reset circuit breaker. Open unit by loosening bottom four screws. Adjust carbon brush for better contact, or replace carbon brush if worn. Inspect and connect any loose wiring. First check connections and reconnect if necessary. Replace potentiometer if faulty. Lightly tap on micro switch to lower it. First inspect connections and reconnect if necessary. If faulty elements, replace as needed. Inspect limit switch assembly for origin of short circuit. Remove brush cap and inspect armature for short. Measure with an ohmmeter across the carbon brush and the outer cover of powerfeed unit. Correct any short circuit in the unit. Repair or replace limit switch. Repair or replace limit switch. Replacement Parts Replacement parts are listed on the following pages. To order parts or reach our service department, call between 7:30am and 5:30pm. (CST), Monday through Friday. Having the Model Number and Serial Number of your machine available when you call will allow us to serve you quickly and accurately. 12

13 Parts Breakdown (All Models) 13

14 Parts List (All Models) Index No. Part No. Description Size Qty 1...TPFA2-A0100N...Top Housing... TPFA-2X TPFA2-P Top Housing... TPFA-2XN TPFA2-A Dial Lock Nut TPFA2-A A...Washer (Optional /not shown) xψ34xψ45mm...N 4...TPFA2-A B...Washer (Optional /not shown) xψ34xψ45mm...N 5...TPFA2-A C..Washer (Optional /not shown) xψ34xψ45mm...N 6...TPFA2-A D..Washer (Optional /not shown) xψ34xψ45mm...N 7...TPFA2-A A...Washer (Optional /not shown) xψ16xψ23.5mm...N 8...TPFA2-A B...Washer (Optional /not shown) xψ16xψ23.5mm...N 9...TPFA2-A C..Washer (Optional /not shown) xψ16xψ23.5mm...N 10...TPFA2-A E...Washer (Optional /not shown) xψ16xψ23.5mm...N 11...TPFA2-A A...Washer (Optional /not shown)... 2xψ16xψ25.4mm...N 12...TPFA2-A0101A...Needle Bearing Assembly A0101B...Inner Ring A0101C...Needle Bearing TPFA2-A Circuit Breaker A Cap of Circuit Breaker A Bushing Bearing... ψ6x ψ12xψ11.5mm A Drive Gear Shaft in/lb P Drive Gear Shaft in/lb TPFA2-A Drive Gear in/lb P Drive Gear in/lb B Bearing ZZ A Light Transmitter TPFA2-A AN Hex Seal Boot (w/ # TPFA2-A N) TPFA2-A Rapid Switch Plunger TPFA2-A Spring TPFA2-A Rapid Switch Housing A Rapid Switch Assembly TPFA2-A Spring TPFA2-A0113N...Adaptor A Spring for clutch A Washer A Washer Bearing A Bearing Cup A Forklift A Washer... 1xψ8xψ18mm A A...Shaft Mount TPFA2-A Spacer TPFA2-C Micro Switch Holder TPFA2-C0506A...Micro Switch Assembly TPFA2-C Switch Actuator TPFA2-C Micro Switch TPFA2-C Capacitor C Micro Switch Holder C Micro Switch Assembly TPFA2-C N..Mounting Plate TPFA2-C Micro Switch TPFA2-D0701N...Bottom Cover in/lb P Bottom Cover in/lb TPFA2-E0901N...Bottom Housing TPFA2-E Cam Assembly TPFA2-E Carbon Brush Holder TPFA2-E Brush TPFA2-E ON/OFF Switch E Cap

15 Parts List (All Models) Index No. Part No. Description Size Qty 62...E Washer E Spring Washer TPFA2-E0912N...Speed Control Knob... 1/4 x1/ P Handle Knob TPFA2-E0913N...Control Knob Assembly P Control Knob Assembly(TPFA2-2Z only) E0913A...Inner Ring TPFA2-E Circuit Board Insulator TPFA2-E Circuit Board Assembly E Strain Relief E Forklift Pin TPFA2-E AL Armature Assembly in/ lb P AL Armature Assembly in/lb TPFA2-E Motor Field E0927A...Bearing Mount E Bushing...ψ8 xψ14.8 x 20mm E Potentiometer Mounting Plate E Collar E Cap E Washer E Nut E0929V...Potentiometer... 10KΩ E Power Cord X3CX2.7M E Crescent Ring... S E Washer xψ38xψ54mm E Spring Washer E Hub F Crescent Ring... IR TPFA2-A E ring... E F E ring... E TPFA2-F Micro Switch TPFA2-F Control Cord x4Cx1.7M G Travel Stop G Nut G Crescent Ring G Spring G Travel Stop Shaft N Nut... M N Nut... M N Nut... 5/ TPFA2-E Carbon Brush Cap TPFA2-E Plastic Gear TPFA2-A Bevel Gear... 5/8 x1/8 (550 in /lb) P Bevel Gear... 5/8 x1/8 (650 in /lb) TPFA2-F Limit Switch Gasket TPFA2-F Limit Switch Cover P Actuator P Forklift Ring TPFA2-F Hold Plate P Drive Gear Assembly TPFA2Z Drive Gear Assembly (TPFA-2Z only) TPFA2-A Driving Shaft (with TPFA2-A03012 Bottom Clutch) TPFA2-C Micro Switch Assembly TPFA2-E Potentiometer Assembly P Zytel Gear Assembly P Limit Switch Assembly

16 Parts List (All Models) Index No. Part No. Description Size Qty P Travel Stop Set P Bevel Gear Assembly... 5/8 (550 in/lb) P01917A...Bevel Gear Assembly... 5/8 (650 in/lb) TPFA2-A Forklift Assembly T Screw... 2x10mm T Screw... 3x15mm T Screw... 3x20mm T Screw... 3x30mm T Screw... 4x6mm T Screw... 4x10mm TPFA2-E Screw... 4x70mm TS Hex Cap Screw... 5/16x T Set Screw... 5x35mm T Set Screw... 4x4mm U Pin... ψ2x24.8mm U Pin... ψ2.5x16mm U Pin... ψ3x15mm U Pin... ψ5x14mm TPFA2-A Pin... ψ2.5x15mm TPFA2-E Pin... ψ3x13.7mm W Spring... 1xψ5xψ12mm W Flat Washer... 1xψ8xψ18mm TS Lock Washer... 4mm D ON/OFF Label Q O Ring... P Electrical Connections 16