Manual - Busy Bee Tools

CX6031-1/2 HP KNEE MILLING MACHINEUSER MANUAL V-1.0

TABLE OF CONTENTSGeneral Safety Instructions for Machines ............................................................... 3Specific Safety Instructions..................................................................................... 4Features.................................................................................................................. 5Physical Features ................................................................................................... 6Proper Grounding ................................................................................................... 7Un-Packing ............................................................................................................. 8Setup ...................................................................................................................... 8Cleaning.................................................................................................................. 8Assembly ................................................................................................................ 9Spindle Lubrication .................................................................................................10ON/OFF Switch.......................................................................................................10Forward/Reverse Switch.........................................................................................10Test Run .................................................................................................................11Table Controls.........................................................................................................11Table Locks ............................................................................................................12Table Limit Stops ....................................................................................................12Down Feed Controls ...............................................................................................13Head Tilting.............................................................................................................13Head Adaptor Rotation ...........................................................................................14Speed Change........................................................................................................14Maintenance ...........................................................................................................15Lubrication ..............................................................................................................15V-Belt Tensioning....................................................................................................17Gibs Adjustment......................................................................................................17Parts Diagram and Parts List ..................................................................................18Warranty .................................................................................................................262

GENERAL SAFETY INSTRUCTIONSFOR MACHINESExtreme caution should be used when operating all power tools. Know your powertool, be familiar with its operation, read through the owner’s manual, and practice safeusage procedures at all times.ALWAYS read and understand theuser manual before operating themachine.CONNECT your machine ONLY to thematched and specific power source.ALWAYS wear safety glassesrespirators, hearing protection andsafety shoes, when operating yourmachine.DO NOT wears loose clothing orjewelry when operating your machine.Wear protective hair covering.A SAFE ENVIRONMENT isimportant. Keep the area free of dust,dirt and other debris in the immediatevicinity of your machine.BE ALERT! DO NOT use prescriptionor other drugs that may affect yourability or judgment to safely use yourmachine.DISCONNECT the power source whenchanging drill bits, hollow chisels,router bits, shaper heads, blades,knives or making other adjustments orrepairs.NEVER leave a tool unattended while itis in operation.NEVER allow unsupervised or untrainedperson to operate the machineNEVER reach over the table when thetool is in operation.ALWAYS keep blades, knives and bitssharpened and properly aligned.ALL OPERATIONS MUST BEperformed with the guards in place toensure safety.ALWAYS use push sticks and featherboards to safely feed your work throughthe machine.ALWAYS make sure that any tools usedfor adjustments are removed beforeoperating the machine.ALWAYS keep bystanders safely awaywhile the machine is in operation.NEVER attempt to remove jammedcutoff pieces until the blade has come toa full stop.3

CX603 – MILLING MACHINESPECIFIC SAFETY INSTRUCTIONSREAD AND UNDERSTAND the usermanual before operating themilling/drilling machine.ALWAYS WEAR safety glasses forthe protection of your eyes whileoperating this machine.WEAR PROPER APPAREL. Looseclothing, gloves neckties, rings,bracelets, or other jewelry may getcaught in moving parts of the machine.Wear protective hair covering tocontain long hair. Do not wear glovesand keep your fingers and hair awayfrom rotating parts.KEEP GUARDS in place. Guardsmust be kept in place and in workingorder to ensure safe operation.MAKE SURE the work-piece isproperly clamped to the table beforeoperating the machine. Never hold thework-piece by hands when using themill.MAKE SURE the cutting tool is sharp,not damaged and properly secured inthe chuck before you start themachine.DO NOT turn the power ON with thecutting tool contacting the work-piece.SELECT THE PROPER SPINDLESPEED for the type of work and materialyou are cutting. Let the spindle reach toits full speed before beginning a cut.DO NOT FORCE THE TOOL. Alwaysuse the machine at the rate for which itis designed. Do not force the machinedoing a job for which it is not designed.NEVER LEAVE the machineunattended while it is running.ALWAYS turn off the power beforeremoving scrap pieces and cleaning themachine.SHOULD ANY PART of your tool bemissing, damaged or fail in any way,shut off the machine immediately andremove the plug from power source.Replace any damaged or missing partsbefore resuming operation.MAKE SURE before installing andremoving any parts, servicing, cleaningor making any adjustments, the switch isin the “OFF” position and the cord is unpluggedfrom the power source.BEFORE OPERATING your CX603milling machine, make sure you haveread and understood all the safetyinstructions in the manual and you arefamiliar with your machine.WARNING!The safety instructions given above can not be complete because the environment inevery shop is different. Always consider safety first as it applies to your individualworking conditions.4

CX603 – MILLING MACHINEFEATURESMODEL CX603 – 1-1/2 HP KNEE MILLING MACHINEAs part of the growing line of Craftex metalworking equipment, we are proud to offer theCX603, a 1-1/2HP Knee Milling Machine. By following the instructions and procedures laid outin this user manual, you will receive years of excellent service and satisfaction. The CX603 is aprofessional tool and like all power tools, proper care and safety procedures should beadhered to.Motor ................................... ..........1-1/2 HP, 220 V, Single PhaseVertical Spindle Taper ......... ..........R8 or MT3 or NT30Vertical Spindle Speeds ...... ..........9 (230 - 2520 RPM)Spindle Travel...................... ..........3-1/8" (80mm)Spindle to Column ............... ..........7-1/2"Spindle to Table Surface ..... ..........0" - 12-3/8" (0 - 345mm)Head Tilt .............................. ..........45° to the Right & 45° to the LeftTable Surface ...................... ..........8" x 30"Max. Table Cross Travel...... ..........6" (150mm)Max. Table Longitudinal Travel.......14-1/2" (370mm)Lead Screw.......................... ..........1" x 8 TPI or 3mm PitchNet Weight........................... ..........450 KgGross Weight....................... ..........540 KgWarranty.............................. ..........3 Years5

CX603 – MILLING MACHINEPHYSICAL FEATURESV-Belt CoverCoarse DownFeed HandleV-Belt TensioningAdjustment BoltFine DownFeed HandWheel1-1/HP MotorLongitudinal LimitStopsForward /Reverse SwitchLongitudinalLocksSwitch Box(ON & OFF)Table HeightCrank HandleLongitudinalHand WheelCross FeedHand WheelColumnBaseCross LimitStopPowderCoated PaintKneeSplash Pan6

PROPER GROUNDINGGrounding provides a path of leastresistance for electric current to reduce therisk of electric shock.To prevent electrical hazards, have aqualified electrician ensure that the line isproperly wired.This machine is for use on a normal 220volts circuit. Make sure that the machine isconnected to an outlet having the sameconfiguration as the plug. If an adaptorplug is used, it must be attached to themetal screw of the receptacle.It is strongly recommended not to useextension cords with your CX603. Alwaystry to position your machine close to thepower source so that you do not need touse extension cords.If it necessary to use an extension cord,make sure the extension cord does notexceed 50-feet in length and the cord is 14-gauge to prevent motor damage. Check forheat build up periodically.Your CX603 should be wired with a 3-prongs plug fitting a 3 prong groundedreceptacles as shown in figure-1. Do notremove the grounding prong to fit it into a 2-pronged outlet. Always check with aqualified electrician if you are in doubt.Figure-1 220-Volts Outlet for CX603WARNING!Improper connection of the equipmentgroundingconductor can result in a riskof electric shock. Check with a qualifiedelectrician if you are in doubt as towhether the outlet is properly grounded.7

UNPACKINGThe machine is properly packaged andshipped completely in crates for safetransportation. When unpacking, carefullyinspect the crates and ensure that nothinghas been damaged during transit. Open thecrates and check that the machine and theparts are in good condition.NOTICEWhile doing inventory, if you can not findany part, check if the part has alreadybeen installed on the machine. Someparts come pre-assembled for shippingpurposes.SETUPBefore setting up your machine you shouldread and understand the instructions givenin this manual.The machine comes mounted to the palletand you need to unbolt it before moving themachine.Use a wrench and unbolt the millingmachine from the pallet.Position the lifting straps around themachine and attach the other ends of thestrap onto the forks of the fork truck. Seefigure-2.Figure-2 Lifting the milling machineWhen setting up your machine, you willwant to find an ideal spot where your millingmachine will most likely be positioned mostof the time. Consider your complete workenvironment before placing your machine inthe ideal spot.CLEANINGThe unpainted surfaces of this table saware coated with a rust preventive waxy oiland you will want to remove this before youbegin assembly. Use a solvent cleaner thatwill not damage painted surfaces.WARNING!CX603 is a very heavy machine, do notover-exert yourself. For safe movingmethod use fork truck. Failure to do socould result in serious personal injuryand damage to the machine.8

ASSEMBLYTo assemble the CX603 milling machine,follow the instructions given below:Thread the handles into the longitudinalhand wheels located on both sides of thetable. See figure-3.The crank handle comes assembled with itsopposite side on the milling machine forshipping purposes.Remove the C-ring securing the crankhandle to the machine and remove thecrank handle.Re-install the crank handle to the millingmachine as shown in figure-5 and secure itusing the C-ring.Figure-3 Installing the handle onlongitudinal hand wheelThread the handle into table cross feedhand wheel located to the front side of themachine. See figure-4.Figure-5 Installing the crank handleFigure-4 Installing handle onto the crossfeed hand wheel9

SPINDLE LUBRICATIONThe milling machine features metal to metalcontacting parts and needs to be properlylubricated to ensure long life andperformance.ON/OFF SWITCHThe switch box on CX603 is located on theright hand side of the machine featuring agreen ON button and a red OFF button.To lubricate the spindle bearings:Lower the down feed handle all way to feedout the quill and rub the quill with a piece orrug having oil on it. See figure-6.Release the down feed handle and let thequill go to it is initial position.Locate the spindle lubrication cup on themill shown in figure-6 and add a few dropsof oil in it.Figure-7 Switch boxFORWARD / REVERSESWITCHCX403 features a forward / reverse switchwhich allows changing the rotating directionof the spindle.Figure-6 Lubrication the spindleWARNING!Lubricating the milling machine properlyis an important task in order to maintainthe machine at a high performancecondition. Failure to follow reasonablelubrication practices could resultpremature failure of your machine.Figure-8 CX603 power cord10

TEST RUNOnce you have assembled your millingmachine completely, it is then time for a testrun to make sure that the machine worksproperly and is ready for operation.WARNING!Before starting the milling machine,make sure that you have read andunderstood the manual and you arefamiliar with the functions and safetyfeatures on this machine. Failure to doso may cause serious personal injury.TO TEST RUN THE CX603:1. Make sure you have read the manualand understood all the safetyinstructions given in it.2. Remove all the tools and objects fromthe machine, used during set up andassembly.3. Make sure the spindle is lubricatedbefore turning the machine ON. Seepage-10 for details.During the test run if there is any unusualnoise coming from the machine or themachine vibrates excessively, stop themachine immediately and disconnect fromthe power source. Investigate to find out theproblem with your machine.7. Now, push the red button and it shouldturn the machine OFF.WARNING!Do not make any adjustments while themachine is running. Turn the machineOFF and un-plug the cord from the powersource before making any adjustments.Failure to do so may cause seriouspersonal injury.TABLE CONTROLSThe table on CX603 features threemovement paths, controlled using crankhandle and hand wheels.See figure-9 for the three different paths inwhich the table can move.4. Make sure the forward/reverse switch isin the OFF position and connect thepower cord to the matched outlet andpush the green button on the switchbox.5. Turn the forward/reverse switch toForward position and verify that themachine is operating correctly.6. Turn the forward/reverse switch to OFFposition and then to Reverse position.See if the spindle rotates in the oppositedirection.Figure-9 Three movement paths for thetable11

LONGITUDINAL HAND WHEELSTheses two hand wheels are located on theleft and right sides of the table and allow tomove the table to the right and to the left.CROSS FEED HAND WHEELThis hand wheel is located on the front sideof the machine and is used to move thetable towards or away from the column.CRANK HANDLEThe crank handle is located on the frontside of the machine, under the table and isused to raise or lower the table.Figure-12 Knee lock and saddle lockTABLE LIMIT STOPSLimit stops limit the travel distance of thetable and saddle and allow repeatabilitywhile operation.Figure-10 Table movement controlsTABLE LOCKSThe table features lock levers to lock thetable in position on each axis, preventing itfrom unwanted movement while operation.Figure-13 Longitudinal limit stopsFigure-11 Longitudinal locksFigure-14 Cross limit stop12

DOWN FEED CONTROLSThis section give you information about thefunctions of the down feed controls.E. DOWN FEED STOPIt stops the down feed assembly at thepoint where it is set.F. DOWN FEED SELECTOR KNOBTightening this knob enables the fine downfeed hand wheel while tightening it enablesthe coarse down feed handle.G. FINE DOWN FEED HAND WHEELIt raises and lowers the down feedassembly in small increment (whenenabled).Figure-15 Down feed controlsH. GRADUATED SCALEShows quill travel in 0.001" incrementswhen fine down feed hand wheel is used.HEAD TILTINGThe mill head on your CX603 tilts 90°left orright.To tilt the mill head:Figure-16 Down feed controlsA. DOWN FEED HANDLEIt is used to raise or lower the quill.Make sure the switch is in the OFF positionthe cord is disconnected from the powersource.Loosen the four hex nuts securing the millhead to the head adaptor on both sides.See figure-17.B. QUILL LOCKIt is used to lock the quill in position.C. DOWN FEED SCALEIt shows the quill movement in inches.D. QUILL DOGIt has a pointer on the side with the downfeed scale and shows the depth of thedown feed.Figure-17 Tilting the mill head13

Tilt the head to the right or left and use thetilt scale to set the head at the correctangle. Re-tighten the four hex nutsproperly, securing the mill head in position.HEAD ADAPTORROTATIONThe head adaptor rotates 360° around thecolumn.To rotate the head adaptor:Make sure the switch is in the OFF positionthe cord is disconnected from the powersource.SPEED CHANGEThe CX603 is a 9-speed (230 - 2520 RPM)milling machine. The spindle speed can bechanged as need for the material being cut.To change the spindle speed:Make sure the switch is in the OFF positionthe cord is disconnected from the powersource.Loosen the lock nut and then bolt shown infigure-19 to release tension on the belt.Loosen the three hex nuts securing thehead adaptor to the column. See figure-18.Figure-19 Releasing tension on the V-beltFigure-18 Rotating the head adaptorArrange the belts, using the table in figure-20 to get the correct RPM for your cuttingoperation and re-tension the V-belt andtighten the bolt and lock nut.Rotate the head adaptor with the head tothe right or left and use the rotation scale toset the head adaptor to the correct angle.Re-tighten the three hex nuts properly,securing the head adaptor in position.Figure-20 Spindle RPM table14

MAINTENANCEDuring the life of your machine, you willneed to practice some regular maintenanceto keep your lathe in peak performancecondition.1. Treat your machine with care, keep itclean and grease and lubricate itregularly. Only through good care youcan be sure that the working quality ofthe machine will remain constant.2. Lubricate all slide ways lightly beforeevery use. The change gears and thelead screw must also be lightlylubricated with lithium based grease.3. During operation, the chips which fallonto the sliding surface should becleaned in a timely fashion. Frequentinspections should be made to preventchips from falling into the positionbetween the work table and the slideways.WARNING!Do not remove the chips with your barehands. There is a risk of cut due tosharp-edged chips. Never useflammable solvents or cleaning agentsor agents that generate noxious fumes.Protect electrical components such asmotors, switches, switch boxes, etc...,against humidity when cleaning.4. Every day, after the operation, eliminateall the chips and clean different parts ofthe machine tool and apply machine tooloil to prevent from rusting.5. Make sure your work area is wellventilated.6. Good housekeeping practice should befollowed on a daily basis keeping yourlathe clean and well lubricated.7. Check the machine everyday beforeoperation for; worn or damaged cord,wire, loose nuts and bolts and makesure all the safety devices are workingproperly.LUBRICATIONThe milling machine features metal to metalcontacting parts and needs to be properlylubricated to ensure long life andperformance.WARNING!Lubricating the milling machine properlyis an important task in order to maintainthe machine at a high performancecondition. Failure to follow reasonablelubrication practices could resultpremature failure of your machine.SPINDLE BEARINGSTo lubricate the spindle bearings:Lower the down feed handle all way to feedout the quill and rub the quill with a piece orrug having oil on it. See figure-21.Release the down feed handle and let thequill go to it is initial position.15

Locate the spindle lubrication cup on themill shown in figure-6 and add 5-6 drops ofoil in it. Practice this after every 8 hours ofuse.LEAD SCREWS & GEARSUse the crank handle and raise the table upto access the gears and lead screwsunderneath the table.Clean the gears and lead screws using ashop rag. Lubricate the gears and leadscrews using #2 grease. See figures below.Figure-21 Spindle bearing lubricationONE-SHOT OILEROpen the fill cap on the one-shot oiler andpour ISO 68 lubricant (or equivalent) in it.The oiler features a sight glass whichshows the amount of oil.Figure-23 Lubrication bevel gears andvertical lead screwsOnce the oiler is filled, pull the handle andrelease it so send lubricant. See figure-22.Figure-24 Lubricating longitudinal leadscrewsFigure-22 One-shot oilerLubricate the machine using one shot oilerafter every 8-9 hours of use (one pumponly).Once you apply the lubricant on the gearsand lead screws, move the table throughthe full range of each lead screw todistribute the lubricant.Lubricate the lead screws and gears in thismanner after every 40 hours of use.16

V-BELT TENSIONINGThe V-belt stretches with use and will needto be tensioned properly.To tension the V-belt:Make sure the switch is in the OFF positionthe cord is disconnected from the powersource.Open the belt cover lock and lift the beltcover up to access the V-belt.Once the V-belt is tensioned properly,tighten the lock nut.GIBS ADJUSTMNETThe table movements along the ways iscontrolled by gibs. Tight gibs increasestable movement accuracy and but make itharder to move. Loose gibs make tablemovement sloppy but easier to move.Gibs should be adjusted so that the tabledoes not move freely and at the same timeit is not hard to move the table.To adjust the gibs:Disconnect the machine from the powersource.Adjust the gibs using a screw driver andmake sure not to tighten the gibsexcessively, failure to do so could resultpremature wear of the sliding parts.Figure-25 V-beltLoosen the lock nut shown in figure-26 androtate the bolt until the V-belt hasapproximately 1/8" of deflection whenmoderate pressure is applied.Figure-26 V-belt tension controlsFigure-27 Adjustment gibs17

WARRANTYCRAFTEX 3 YEARS LIMITED WARRANTYCraftex warrants every product to be free from defects in materials and agrees to correct such defects whereapplicable. This warranty covers three years for parts and 90 days for labor (unless specified otherwise), to theoriginal purchaser from the date of purchase but does not apply to malfunctions arising directly or indirectly frommisuse, abuse, improper installation or assembly, negligence, accidents, repairs or alterations or lack ofmaintenance.Proof of purchase is necessary.All warranty claims are subject to inspection of such products or part thereof and Craftex reserves the right toinspect any returned item before a refund or replacement may be issued.This warranty shall not apply to consumable products such as blades, bits, belts, cutters, chisels, punchesetceteras.Craftex shall in no event be liable for injuries, accidental or otherwise, death to persons or damage to property orfor incidental contingent, special, or consequential damages arising from the use of our products.RETURNS, REPAIRS AND REPLACEMENTSTo return, repair, or replace a Craftex product, you must visit the appropriate Busy Bee Tools showroom or call 1-800-461-BUSY. Craftex is a brand of equipment that is exclusive to Busy Bee Tools.For replacement parts directly from Busy Bee Tools, for this machine, please call 1-800-461-BUSY (2879), andhave your credit card and part number handy. All returned merchandise will be subject to a minimum charge of 15% for re-stocking and handling with thefollowing qualifications. Returns must be pre-authorized by us in writing. We do not accept collect shipments.Items returned for warranty purposes must be insured and shipped pre-paid to the nearest warehouseReturns must be accompanied with a copy of your original invoice as proof of purchase. Returns must be inan un-used condition and shipped in their original packaging a letter explaining your reason for the return.Incurred shipping and handling charges are not refundable.Busy Bee will repair or replace the item at our discretion and subject to our inspection.Repaired or replaced items will be returned to you pre-paid by our choice of carriers.Busy Bee reserves the right to refuse reimbursement or repairs or replacement if a third party without ourprior authorization has carried out repairs to the item.Repairs made by Busy Bee are warranted for 30 days on parts and labour.Any unforeseen repair charges will be reported to you for acceptance prior to making the repairs.The Busy Bee Parts & Service Departments are fully equipped to do repairs on all products purchased from uswith the exception of some products that require the return to their authorized repair depots. A Busy Beerepresentative will provide you with the necessary information to have this done.For faster service it is advisable to contact the nearest Busy Bee location for parts availability prior tobringing your product in for repairs.26