Page 2
ATTENTION We are grateful that you have chosen our product! We are confident that our Milling Machines will satisfy your expectations with their many outstanding features, such as: rigidity, high accuracy, versatility, etc. In order to achieve the highest possible performance from our machines, we expect all operators and those concerned with maintenance to READ THIS MANUAL CAREFULLY BEFORE STARTING.
CONTENT Page# 1. SAFETY INSTRUCTIONS 1-1. General Safety Instructions For Operating The Machine 1-1-1 Safety instructions for work holding 1-2. Maintenance Safety Instruction 1-3. Installation Precautions 1-3-1 Grounding 1-3-2 Environmental conditions 1-4. Safety Precaution 1-4-1 Before powering on the machine 1-4-2 Routine inspections 1-4-3 Warm-up 1-4-4 Preparations...
Page 4
Page# E. Electrical Part List with Part Number Listed F. Amendment of UL Part List (File No: TR14101501; Date: 4/11/19) 4-7. Alignment of Head 5. LUBRICATION 5-1. Lubrication System of e-mill 3VS and 3VSII 5-2. Lubrication System of e-mill 3VK 5-3.
Page 5
Page# 7-10-1. Daily maintenance 7-10-2. Weekly maintenance 7-10-3. Six month maintenance 7-10-4. Yearly maintenance 7-10-5. Points to watch on doing maintenance 7-11. Tables for Material Cutting Information 8. MECHANICAL DRAWING & PARTS BREAKDOWN LIST 8-1 3HP (Milling Head) 8-2. 3HP Head Top Housing 8-3.
1. SAFETY INSTRUCTIONS WARNING Do not install, operat e or service this machine until : 1) You have read and understand the safety instructions on the pages that follow. 2) You have read and understand the operator’s manual, especially knowing the function and location of all machine controls, and read manuals on all relative accessories.
Page 7
5) Keep the machine and area around it clean and well lighted. Never allow chips, coolant or oil to remain on the floor. Do not leave loose objects on and around the machine. 6) Clothing : * Wear safety glasses with eye shields at all times. Protect your eyes. Never use a compressed air house to remove chips from a machine.
20) Coolant and oil can make surfaces on the machine slippery. They can also present an electrical hazard if the machine has power on. For these reasons, please do not stand on any part of the machine at any time. 1-1-1 Safety instructions for work holding 1) Never run a job on this machine until you are 100% sure the work piece is being held in such a manner as withstand the centrifugal force from rotation and...
5) Always be sure the tool holder or accessory is locat ed correctly on the spindle taper and it is securely pulled to the face of the spindle. 6) Be sure any item bolted or clamped to a vise or fixture is securely fastened before starting the spindle.
Wiring 1) Be sure to use electrical conductors with performance ratings equivalent or superior to those described in the Maintenance Manual. 2) Do not connect to the same power distribution panel that is intende d for devices, which can cause line noise, such as, welders and high frequency quenching machines.
Common grounds: Resistance ground number of devices connected to the grounding (Ω) Never ground equipment as shown in the lower figure (FORBADE!) : (Wrong) 1-3-2. Environmental conditions Generally, the machine will be installed at the places wi th the following conditions. However, these may change over a period of time or in response to seasonal changes.
Page 12
Basic Operating Practices DANGER 1) Some control panels, transformers, motors junction boxes and other parts have high-voltage terminals, these should not be touched or a severe electric shock will be sustained. 2) Do not touch a switch with wet hands. This, too, can cause an electric shock. WARNING 1) The emergency stop push -button should be well known so that it can be operated at any time without having to look for it.
1-4-1. Before powering on the machine DANGER Cables, cords or electric wires whose insulation is damaged can cause current leaks and electric shocks. Before using them on any machine, please check their conditions. WARNING 1) Be sure the instru ction manual or the operation manual is fully understood. Every function and operation should be completely clear.
CAUTION 1) Check lubrication gauge for proper reading (only for 6VK) . 2) Check spindle, coolant motor (only for 6VK), powerfeeds (only for 6VK) and other parts for abnormal noises. 3) Check the motor lubrication and sliding parts for evidence of proper lubrication. 4) Check safety covers and safety devices for proper operation (optional accessories).
All machineries make sound when operating. With an assistance from noise dosimeter, the noise level generated when cutting a work piece on ACER mills is recorded at 76.07 dB(A). This is documented as follows, Equivalent A-weighted Sound pressure level according to EN ISO 3746: 76.07 dB(A) Uncertainty, K in decibels: 4.0 dB (A) according to EN ISO 4871...
be used reliably to determine whether or not further precautions are required. Factors that influence the actual level of exposure of the workforce include characteristics of the work room, the other sources of noise, etc. i.e. the number of machines and other adjacent processes. Also the permissible exposure level can vary from country to country, this information, however, will enable the user of the machine to make a better evaluation of the hazard and risk.
8) Clean the coolant filter and tank routinely. 1-4-9. Safety devices 1) Table guard with doors (optional). 2) Chip pan (6VK only). 3) Column side guard (optional). 4) Travel limit switches (6VK only). 5) Emergency stop push buttons. 1-4-10. Maintenance operation p reparations 1) Do not proceed with any maintenance operation unless being instructed to do by the foreman.
2) Over-travel limit and interlock mechanisms including functional parts should not be removed or modified. 3) When working at a height level, please use steps or ladders which are maintained and controlled daily for safety. 4) Fuses, cables, etc. should be made by qualified manufacturers and then they can be deployed.
Page 19
Labels are numbered as above! The label positions for e-mill 3VS, 3VSII, 3VK, 3VKH, and 5VK are indicated on the photo by numbers. (Model machine shown is e-mill 3VK!) - 18 -...
Page 20
The label positions for e-mill 6VK are indicated on the photo by numbers. (Note: Label #1 for 5VK is also located at the shown position.) - 19 -...
Page 24
7 x 10 ft. (2.1 x 3.1m) Height 96 in. (2438mm) Net Weight 3300 lbs. (1500kgs) Shipping Weight 3498 lbs. (1590kgs) Power Electrical Supply – 60/50 phase 220/230/380/415/ 440/460/575V Color Standard Machine Gray/ACER White with Burgundy Stripes - 23 -...
Page 26
3.1m) Height 96 in. (2439mm) Net Weight 3550 lbs. (1614kgs) 3700 lbs. (1682kgs) Shipping Weight 3749 lbs. (1704kgs) 3899 lbs. (1772kgs) Power Electrical Supply – 60/50 phase 220/230/380/415/ 440/460/575V Color Standard Machine Gray/ACER White with Burgundy Stripes - 25 -...
Page 27
e-mill 5VK 2" 2 1/4" Min. 50mm 57mm 22 1/2" 23 3/4" Max. 572mm 603mm Figure 4. Principal Dimension of 5VK - 26 -...
Page 28
3.1m) Height 96 in. (2439mm) Net Weight 3750 lbs. (1705kgs) 3900 lbs. (1773kgs) Shipping Weight 3949 lbs. (1795kgs) 4099 lbs. (1863kgs) Power Electrical Supply – 60/50 phase 220/230/380/415/ 440/460/575V Color Standard Machine Gray/ACER White with Burgundy Stripes - 27 -...
Page 29
e-mill 6VK 2" 2 1/4" Min. 50mm 57mm 22 1/2" 23 3/4" Max. 572mm 603mm Figure 5. Principal Dimension of 6VK - 28 -...
Page 30
7 x 10 ft. (2.1 x 3.1m) Height 95 in. (2413mm) Net Weight 4960 lbs. (2255kgs) Shipping Weight 5181 lbs. (2355kgs) Power Electrical Supply – 60/50 phase 220/230/380/415/ 440/460/575V Color Standard Machine Gray/ACER White with Burgundy Stripes - 29 -...
2-2 Milling Head Specification Milling Head Specification 3VS/3VSII/3VK 3VKH Model 3 HP (2.25KW) 5 HP (3.75KW) Power 1750 Motor RPM Speed Range RPM Variable Speed 0~520 0~560 High 500~4500 500~4500 5" (127mm) Quill Travel 3.375" (86mm) 3.94" (100mm) Quill Diameter NST/ISO #40 Spindle Taper 2.677"...
2-3 Features & Description of Machines e-mill 3VS & 3VSII (Note: e-mill 3VK has similar features!) Features of 3VS & 3VSII Item# Description Item# Description Item# Description Ram Adaptor One-shot Lube Column Dovetail Way Knee Crank Handle Spindle Turret Dish-in Base Head Housing Column Pedestal...
Page 33
e-mill 3VKH (Note: e-mill 5VK has similar features except no ram adaptor!) Features of 3VKH Item# Description Item# Description Item# Description Ram Adaptor One-shot Lube Column Dovetail Way Knee Crank Handle Spindle Turret Dish-in Base Head Housing Column Pedestal Control Panel Electric Cabinet Knee Spindle Motor...
Page 34
e-mill 6VK Features of 6VK Item# Description Item# Description Item# Description Auto Lubricator Table Lock Turret Chip Pan Table Halogen Light Dish-in Base Table Stop Bracket Coolant Nozzle Pedestal Column Square Way Column Knee Crank Handle Spindle Table Dovetail Way Elevation Motor Operation Panel Saddle Lock...
3. UNCRATING & CLEANING Carefully remove protective crating so machine and parts are not marred or damaged. In the event of damage in transit, immediately notify the distributor from whom the machine was purchased, as well as the transportation company making delivery.
4-1 Lifting Machine The column and base are a one -piece casting. Machi ne should be lifted by placing a sling under the ram. (Sling is made from polyester webbing and flat nylon, 2” wide, 1/5” thickness , 8 meters length and rated breaking strength at 4,400lbs or 2,000kgs.) Note: Position of ram and table when lifting with a sling.
Page 37
e-mill 3VK Figure 7. Lifting method of e -mill 3VK - 36 -...
When setting machine on a floor that has any surface irregularities , shims should be used to correct this condition to the greatest extent possible . See figure illustrated for installation layout. e-mill 3VS & e-mill 3VSII Figure 9. Installation layout - 38 -...
Page 40
NOTE IT IS RECOMMENDED TH AT THE MACHINE BE SECURED TO THE FLOOR TO PREVE NT MOVEMENT OR TIPPING DUE TO OF F-CENTER LOADING. Before securing machine to floor (i.e. tightening hold down bolts) make certain all four corners are ma king contact with floor after machine is leveled. If above condition is not met, it is possible to twist the column and put a bind into the ways .
4-3 Leveling Machine Set machine by leveling the work table lengthwise and crosswise with engineering precision levels. 4-4 Handles When crating, the three ball crank handles are sometimes turned to face the machine. In this case the handles should be reversed before opera tion. 4-5 Connecting Power S upply To connect the machine to the plant’s power source, please have a qualified electrician proceed as follows:...
Page 44
2. Connect machine wiring to power supply making sure connection is in compliance with all local electrical codes and safety regulations . 3. Check for correct spindle rotation. In the HIGH SPEED range, the spindle should rotate clockwise when viewed from the to p of the machine. NOTE DRUM SWITCH AND HI -NEUTRAL-LO LEVER MUST BE IN “HI”...
Page 63
Control Panel Item# Part# Description 9500 Emergency Switch 9501 F/R Switch 9502 Variable Resistor 9503-2 Digital Counter Input power at 230V/3P/60HZ, the power disconnect breaker is at 25A, wiring must be 3.5mm or greater. Input power at 460V/3P/60HZ, the power disconnect breaker is at 20A, wiring must be 3.5mm or greater.
4-7 Alignment of Head: In case of precision work where it is necessary to have head perfectly square with the table, please use method described below. To set head square to table, see figure 13 for 3VS, 3VK, and 3VKH & figure 14 for 5VK and 6VK. This must be done with Ram A dapter on Ram by adjusting Ram A dapter through vertical adjusting worm shaft.
5. LUBRICATION Do not operate machine until properly lubricated: (A)Way surfaces and lead screws (Sunoco waylube #80 or equivalent); one pump daily. (B)Milling head and spindle bearings (S.A.E. 10 or 10W light oil) ; weekly. (C)Elevation screw (Shell Carnea Oil 41); twice weekly. (D)Motors are greased for life of bearings.
5-5. Lubrication Schedule for A ll e-mills LUBRICATING AREA LUBRICANT FREQUENCY QUANTITY SHELL CORNEA OIL 41 MOBIL VACTRA #2 X & Y LEAD SCREWS SONOCO GARGOYLE VACTRA NO. 2 CENTRALIZED LUBRICATION FEW PUMPS DAILY SADDLE TABLE PUMP DAILY UNTIL VISUALLY WAYS CHECK LEVEL SEEING OIL...
6. OPERATION Note: Safety operation rules review 1. SECURE WORK. Use chuck to hold work piece when it is practical. It is safer than using your hand and this way it frees operator’s hands to operate the lathe. 2. DO NOT OVERREACH. Keep proper footing and balance at all times. 3.
Page 93
20. Never use the high spe ed range continuously over one hour. 21. KEEP CUTTING TOOLS TIGHT during operation. - 92 -...
6-2 Draw Bar DO NOT attempt to change spindle RPM u nless the motor is running, expressed speeds will only be approximate. Belt wear will cause variations in speed, from the speed indicated by the digital counter . When tightening or loos ening the drawbar, it is necessary to lock the spindle. To do this, use the spindle brake (5 ) which is located on the left side of the belt housing.
CAUTION DO NOT SHIFT HI-LO LEVER WHILE THE M OTOR IS RUNNING. 6-6 Power Feed Engagement Crank(#7) Engages power feed worm gear. When lever is in right hand hole, power feed is engaged. To disengage, pull knob out and turn crank clockwise and move to opposite position.
quill feed handwheel may be disengaged by moving them outward approximately ”. NOTE The feed control lever must be engaged in order to use manual feed controls. The Quill Feed hand le and Manual Feed Handwheel may be taken off when not in use. 6-10 Feed Control Lever (#11 on 5HP &...
6-15 Ram Position A. Ram can be moved by loosening three ram lock studs on turret and moving to desired position. CAUTION CARE SHOULD BE TAKEN TO LOCK RAM SECURELY AFTER SETTING. NOTE It is recommended that on heavy milling work, head should be kept as close to column as possible, where maximum rigidity is obtained.
Page 100
for heavier cuts with a minimum of vibration. The saddle locking lever is located on the left-hand side of the saddle. Excessive pressure can cause slight table bind. Use moderate clamping pressure, as this will hold saddle sufficiently. The table clamp levers are located on the front of saddle and should always be clamped when longitudinal movement is not required.
For 3VS, 3VSII & 3VK For 3VKH, 5VK & 6VK Figure 17. Knee clamping lever 6-17. Operation Recommendations Use 2, 3, or 4 flute end mills. Eight flute end mills are usually not as satisfactory for general milling. When using shell mills, face mills or any other tooling, proper machining practice should be observed.
Page 102
When shifting to “LO” DO NOT FORCE THE LEVER if the back -gears to not mesh. Hold the lever so that the gears are clear of one another, r otate the spindle nose by hand until the gears line up, then put the unit in “LO” (back -gear). 500 to 4500 RPM is obtained through the direct drive and is referred to as high range.
7. MAINTENANCE 7-1 Adjustment of Table Gib: The table is provided with a full length tapered gib in the saddle, and an adjusting screw on the left side. To take up gib, tighten g ib adjusting screw slightly and repeat until a slight drag is felt when moving the table by hand. For 3VS, 3VSII, 3VK For 3VKH, 5VK &...
Adjustment of knee g ib: Remove chip wiper and adjust screw until smooth movement is attained. Replace chip wiper. For 3VS, 3VSII, 3VK For 3VKH, 5VK & 6VK Figure 20. Knee/column gibs 7-3 Removing Table & Saddle Remove the following: ball crank, handles, dial holders and bearing brackets. Remove the lead screw and slide the tabl e from the saddle.
Cross leadscrew adjustment Crank the saddle to middle position, withdraw 4 screws “D”, pull the saddle forward to expose screws “B”, unscrew screw “B” a few turns, slowly turn handle “C” while tightening adjusting nut until 0.004” or 0.005” is obta ined. Lock screw “B”...
7-6 Changing the Vari -drive Belt—the V Belt Complete the previous procedures for removing the motor then remove the three screws (A) and lift out the top bearing cap (B). Next remove the six screws (D), then holding the belt housing (E) to the base. Remove the old belt and replace it with a new belt.
7-8 Returning Spring Replacement Move quill to top p osition and apply quill lock, remove screw (A), hub (B) and key (C) and screws (D), allowing housing to rotate slowly releasing spring tension. Lift end of spring from peg on the pinion shaft. Rotate Housing (E) counter -clockwise from head casting, remov e spring from housing.
7-9. Recommended Spare Part List Spare parts are always a concern for the users. Below lists are recommended by the manufacturer. The time frame for the using the spare parts are estimated at one to two years depending on the machines’ usage. Please carefully select and pur chase the parts needed for individual mill.
7-10. Recommended Maintenance Schedule 7-10-1. Daily maintenance: 1. Check the oil level of lubrication pump. Add more if it is below low level. 2. Check all lubrication points to see if oil is present? 3. Check coolant pump to see if it is still operational? (6VK only) 4.
5. Replace V-belt on the top housing to ensure power transferring efficiency. 6. Check all function on the machine, ie, automatic downfeed, spindle RPM, etc., to ensure machine’s workabilit y. 7. Clean all leadscrews, and replace with new lubricant. 8. Remove all gibs, clean, and re -install them to original specification. 9.
7-11. Tables for Material Cutting Information GENERAL SPEED RECOMM ENDATIONS Feet Per Minute Material to be Cut Rough Rough Light and Finish Finish Cast Iron - Soft (Under 200 Brinnell) 80-90 Cast Iron - Med (200-300 Brinnell) 60-70 Cast Iron - Hard (Over 300 Brinnell) 50-60 Steel (Chrome Nickel 40 -45 Shore) Steel (Stainless)
8. Mechanical Drawings & Parts Breakdown List Note: When ordering parts, please be prepared with, 1. Machine model & serial number. 2. Item number. 3. Part number and description. 4. Year of Production. 5. Voltage & horsepower. 6. Quantity - 116 -...
Page 137
3HP Head Back Gear ITEM NO. PARTS NO. FACTORY NO. DESCRIPTION Q'TY H8053-2 VS50-2 Belt Housing Base H8064 VS51 Socket HD Cap Screw 8034-5 VS70-1 Spindle Pulley Hub 8027-1 VS04-1 V Belt 8049-1 VS71-1 8063-2 VS07-1 Grease Add Name Plate 8059 Drive Screw 8063-3...
8-16. Electric Cabinet ITEM PART FACTOTRY DESCRIPTION QT'Y 3V-B001 Electric Cabinet UL 9600-1 Electric Cabinet 9750-A Door Hinge Female 3V-B002 Main Cabinet Cover UL 9619-1 Main Cabinet Cover 9750-B Door Hinge Male M6x1x12 Socket HD Cap Screw 3V-B003 Inverter Locating Plate UL 9602-1 Inverter Locating Plate M6 Narrow...
8-17. Safety Accessories for All Models ITEM NO. PART NO. DESCRIPTION QT'Y Chip Pan for 3VS, 3VK 9753 Chip Pan for 3VKH, 5VK 9753-1 Column Guard-Right 9754 Column Guard-Left 9755 ACU-F06A_1050 Table Guard for 50” Table ACU-F06A_1054 Table Guard for 54” Table Table Guard for 42”...