Hafco Metalmaster HM-46B Operation Manual Download

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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 fire 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 modifications 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.



DISCONNECTION 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 floor.



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.

07/11/2019

Instructions Manual for HM-46B (M138D)

Summary of Contents for HM-46B

Page 1: ...DRILL MILL OPERATION MANUAL Edition No HM 046 1 Date of Issue 10 2019 Model HM 46B Order Code M138 M138D 07 11 2019 Instructions Manual for HM 46B M138D 1 ...

Page 2: ... NO DATE OF MANF NOTE This manual is only for your reference Owing to the continuous improvement of the HAFCO METALMASTER machines changes may be made at any time without obligation or notice Please ensure the local voltage is the same as listed on the specification plate before operating this electric machine Distributed by www machineryhouse co nz MACHINE DETAILS 07 11 2019 Instructions Manual f...

Page 3: ...ing 10 3 4 Electrical Installation 11 3 5 Full Load Current Rating 12 3 6 Basic Controls 12 3 7 Test Run 13 4 OPERATION 4 1 Operation Overview 15 4 2 Downfeed Controls 16 4 3 HeadstocK Movement 17 4 4 Table Movement 18 4 5 Installing and Removing The Tooling 19 4 6 Digital Angle Block 20 4 7 Changing The Speeds 20 5 OPERATION INSTRUCTION 5 1 Lubrication 22 5 2 Changing The Gearbox Oil 22 5 3 Gib A...

Page 4: ... 5 2 Voltage Amperage 240 10 140 10 Dimensions L x W x H cm 84 x 77 x115 84 x 77 x115 Weight kg 293 293 Digital Readout 3 Axis Counter X Y Scales only X Axis Power Feed Optional Optional Draw Bar Size 1 off 1 2 x 12 TPI 1off M12 x 1 75mm 1 2 x 12 TPI 1off M12 x 1 75mm 1 Bevel angle box 2 16mm Drill Chuck and Arbour 3 Mt3 x MT2 Drill sleeve 4 Mt3 x 45mm Face Mill 5 3 x TPMN16 inserts 6 Instruction ...

Page 5: ... Axis Table Lock Q Fine Down feed Handle D Down feed Selector Knob K Y Axis Handle R Depth Stop Scale E Course Down feed Handle L Table Travel Stop S Control Panel F Dovetail Column M Vertical Handle T Speed Selectors G X Axis Handles N Spindle U Drawbar Cover A B C D E F G I H K J L M N O P Q U G R S T 07 11 2019 Instructions Manual for HM 46B M138D 5 ...

Page 6: ...facturer will not be held liable for injury or property damage from negligence improper training machine modifications 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 hearin...

Page 7: ...e job safely Obtain first aid immediately for all injuries Understand that the health and fire hazards can vary from material to material Make sure all appropriate precautions are taken Clean machines and the surrounding area when the operation is finished Use proper lock out procedures when servicing or cleaning the machines or power tools DO NOT Do not distract an operator Horseplay can lead to ...

Page 8: ...nd the material Feed the workpiece against the milling cutter ENDING OPERATIONS AND CLEANING UP Switch off the machine when work completed Remove milling cutters and store them safely Before making adjustments and measurements or cleaning swarf accumulations switch off and bring the machine to a complete standstill Leave the machine and work area in a safe clean and tidy state POTENTIAL HAZARDS AN...

Page 9: ...2 2 Note The manufacturer recommends not to exceed 90 angle Fig 2 2 Fig 2 1 When lifting the machine only certified lifting slings should be used Ensure that when lifting the machine does not tip over Check that the lifting slings do not interfere with the hydraulic pipes or electrical conduits Failure to follow these instructions could cause damage to the machine 1 Move the shipping crate next to...

Page 10: ... If the machine is to be installed in a commercial or workplace setting or if it is permanently connected hardwired to the pow er supply then the stand should be anchored to the floor M0015 Order Code M0015 Whether you mount your machine to the cabinet stand or to an existing workbench it must be leveled If you mounted your machine to an existing workbench use a precision level and metal shims as ...

Page 11: ...mize the risk of electrocution fire or equipment damage the installation and electrical wiring must be done by a qualified electrician NOTE The use of an extension cord is not recommended as it may decrease the life of electrical components on your machine 3 4 ELECTRICAL INSTALLATION ELECTRICAL REQUIREMENTS Nominal Voltage 240V Cycle 50 Hz Phase Single Phase Power Supply Circuit 10 Amps Full Load ...

Page 12: ...overheating or fire may be caused to the motor and circuitry This is especially true if connected to an undersized circuit or a long extension lead To reduce the risk of these hazards avoid overloading the machine during operation and make sure it is connected to a power supply circuit that meets the requirements 3 5 FULL LOAD CURRENT RATING 3 6 BASIC CONTROLS The descriptions below can be used to...

Page 13: ...the mill drill without oil in the reservoir will not be covered under warranty Test run the machine to ensure it is properly connected to power and safety components are functioning correctly If you find an unusual problem during the test run immediately stop the machine disconnect it from power and fix the problem BEFORE operating the machine again Consult The Troubleshooting table in the mainten...

Page 14: ...little to no vibration or rubbing noises 7 Press STOP button D in Fig 3 5 and wait for spindle to completely stop 8 Press SPINDLE REVERSE button B in Fig 3 5 Spindle should rotate counterclockwise as viewed from top 10 Press EMERGENCY STOP button E in Fig 3 5 and wait for spindle to completely stop 11 Without resetting EMERGENCY STOP button press SPINDLE FORWARD button Machine should not start NOT...

Page 15: ...xamines the workpiece to make sure it is suitable for the machining operation 2 Check the machine to ensure that it is safe to use and put on protective clothing and safety equipment 3 Place the workpiece on the table and securely clamp it to the table 4 Select the correct cutting tool for the job and with the machine disconnected from power install the cutting tool using the correct holder 5 Lowe...

Page 16: ...eed selector knob to engage coarse down feed handles 3 Position depth stop with adjustment knob 4 Use coarse down feed handles to raise and lower the spindle To Use The Fine Down feed 1 Loosen quill lock lever 2 Tighten down feed selector knob to engage fine down feed hand wheel 3 Position depth stop with adjustment knob 4 Rotate fine down feed hand wheel to raise and lower spindle Depth Stop The ...

Page 17: ...5 and one under the bottom of the head see Fig 4 6 NOTE The 3 nuts must only be loosened a quarter to a half a turn maximum to avoid the head disengaging from the tilting mechanism and the head dropping under its own weight 3 Using the scale shown as a guide swivel the headstock and re tighten the three hex nuts to secure it 3 Use Z axis crank shown in Fig 4 4 to adjust the headstock height 4 Tigh...

Page 18: ...al can be adjusted to a relative starting point Fig 4 8 9 Fig 4 8 Cross Dial Fig 4 9 Longitudinal Dial Before moving the table make sure that the table lock for that movement has been unlocked Always lock the table if not using the movement in that direction Fig 4 10 NOTE When tightened table locks provide table rigidity in that path of table travel for increased precision Left to Right Movement X...

Page 19: ...from the top thread the drawbar by hand into the tooling until it is snug then use a spanner to tighten it 5 Replace the drawbar cap To remove the tooling 1 DISCONNECT THE MACHINE FROM POWER 2 Remove the drawbar cap 3 Un thread the drawbar from tooling one full rotation NOTE Do not fully un thread the tooling from the drawbar or the drawbar and tool threads could be damaged in the next step 4 Tap ...

Page 20: ...angle gauge Operation The operation of the digital angle gauge is very simple Press the ON OFF button to switch on the gauge and press the ZERO button at anytime to zero the gauge Fig 4 14 To set true Zero find a level surface and place the angle gauge on the surface switch on the dig ital angle gauge and press zero It will remember zero until the ZERO button is pressed again Fig 4 14 4 7 CHANGING...

Page 21: ...peed These sources also provide a wealth of additional information about the variables that affect cutting speed and they are a good educational resource Also there are a large number of easy to use spindle speed calculators that can be found on the internet These sources will help you take into account the applicable variables in order to determine the best spindle speed for the operation SETTING...

Page 22: ...e filled with oil such as SAE 68 to the level in the sight glass CHANGE OIL EVERY 12 MONTHS 5 Apply oil to quill pinion EVERY 90 DAYS NOTE Use extreme care when performing these operations and keep hands clear of pinch points Do not apply with motor running 5 2 CHANGING THE GEAR BOX OIL The headstock oil should be changed every 12 months To Change The Oil 1 Run the spindle for 5 or 10 minutes at 5...

Page 23: ...n pressure between the sliding surfaces The process of properly adjusting the gibs requires trial and error and patience Refer to Fig 5 2 5 4 to identify the locations of the table saddle and column gibs and one of the two adjustment screws for each NOTE It will be necessary to remove small parts such as way wipers and covers to access the gib adjustment screws The following is the method used to ...

Page 24: ...ctly or use slower feed rate 2 Use larger cutting tool and slower feed rate 3 Use coolant or oil for appropriate application 4 Lessen depth of cut and allow chips to clear 5 Fully retract spindle and raise table This increases rigidity 1 Tighten table locks 2 Properly clamp workpiece on table or in vise 3 Set spindle speed correctly or use slower feed rate Page 20 21 4 Fully retract spindle and ra...

Page 25: ... time without notification HOW TO ORDER SPARE PARTS 1 Have your machines model number serial number date of manufacture on hand these can be found on the specification plate mounted on the machine 2 A scanned copy of your parts list diagram with required spare part s identified 3 Go to www machineryhouse com au contactus and fill out the enquiry form attaching a copy of scanned parts list 07 11 20...

Page 26: ...26 OPERATION MANUAL HEAD PARTS DIAGRAM 07 11 2019 Instructions Manual for HM 46B M138D 26 ...

Page 27: ...w Oil Pointer I Shaft Gear Z14 Bearing Bearing Key Ii Shaft Gear Z29 Gear Z35 Gear Z21 Gear Z41 Bearing 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 1 1 2 2 2 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6X14 6X28 φ8 φ18 5X50 M6X12 20107B 20109 B 20110 2 B 20112 B 20113 B 20115 B 5X50 6X18 6X18 20019 20104B 30207 P5 30...

Page 28: ... R8 Worm Wheel Box Worm Shaft Worm Cover Screw Separating Ring Worm Wheel Pinion Shaft Handle Body Spring Base Spring Cap Spring Plate Big Ripple Handle Compression Spring Graduated Plate Handle Rod Handle Ball Handle Wheel Handle Rod Screw Screw Washer Screw Screw Screw Pin Key Screw Pin Fixed Bolt Fixed Tight Block Fixed Tight Block 108 109 110 111 112 113 114 115 116 117 118 119 1 1 1 1 2 2 1 2...

Page 29: ...29 OPERATION MANUAL COLUMN AND TABLE PARTS 07 11 2019 Instructions Manual for HM 46B M138D 29 ...

Page 30: ...Washer Bolt Washer Screw Plate Protecting Cover Screw Pin Pipe Joint Filter Screen Screw Center Base Table Table Nut Table Base Nut Right Flange Left Flange Table Screw 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 3 1 3 2 1 2 1 4 2 2 1 2 1 1 2 2 1 1 1 2 2 1 2 7 1 1 1 1 1 3 3 3 M6x16 10105 6 M5X20 M8X45 M8X15 10022 M8X25 10108 10109 10023 M6 X 16 1...

Page 31: ...31 OPERATION MANUAL WIRING DIAGRAM 07 11 2019 Instructions Manual for HM 46B M138D 31 ...

Page 32: ...re connecting 14 Use correct amperage extension cords Undersized extension cords overheat and lose power Replace extension cords if they become damaged 15 Keep machine well maintained Keep blades sharp and clean for best and safest performance Follow instructions when lubricating and changing accessories 16 Keep machine well guarded Make sure guards on machine are in place and are all working corr...

Page 33: ... inspection Inspect Drill and end mills for sharpness chips or cracks before use Replace any cutting tools immediately if dull chipped or cracked Handle new cutting tools with care Cutting edges are very sharp and can cause lacerations 9 Reversing the spindle Make sure the spindle has come to a complete stop before changing the direction of the spindle Do not slow or stop the spindle by using you ...

Page 34: ...DIUM Eliminate avoid loose clothing Long hair etc Incorrect adjustment may result in the head becoming detatched and a crushing hazard Mill head tilting adjustment please refer to mill head tilting instruction sheet for correct procedure Make sure all guards are secured shut when machine is on HIGH MEDIUM Ensure correct spindle direction when milling Ensure tooling is secure in chuck Stand clear o...

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