SHOP FOX D3694 (01) PDF Document

Motor Specifications:

Type: Class E, Brush Type 110VDC

Horsepower: 0.2 HP

Amps: 1.8A

Watts: 1500W

Speed: 4000 RPM

Cycle: 60 Hz

Power Transfer: Gearbox w/All Steel Gears

Bearings: Bushing and Permanently Lubricated Ball Bearing

Overall Dimensions:

Weight: 13 lbs.

Width/Depth/Height: 7¾” x 7½” x 5″

Electrical Specifications:

Switch: Dual Micro Limit Switch

Power Supply Voltage: 110V

Cord Length: 7 ft.

Cord Gauge: 18 gauge

Recommended Breaker Size: 15 amp

Plug: NEMA 5-15

Power Supply: 110VAC, Single-Phase

Circuit Board Protection: Fuse, 5A

Automatic Motor Overload Protection: Circuit Board Controlled Motor Shutdown

Motor Control: Circuit Board w/Rheostat

Rapid Feed Speed Option: Yes, Push Button

Feed Speed Range: 0-1100 mm/min

1. READ THROUGH THE ENTIRE MANUAL BEFORE STARTING MACHINERY. Machinery presents serious injury hazards to untrained users.

2. ALWAYS USE ANSI APPROVED SAFETY GLASSES WHEN OPERATING MACHINERY. Everyday eyeglasses only have impact resistant lenses, they are NOT safety glasses.

3. ALWAYS WEAR AN ANSI APPROVED RESPIRATOR WHEN OPERATING MACHINERY THAT PRODUCES DUST. Wood dust is a carcinogen and can cause cancer and severe respiratory illnesses.

4. ALWAYS USE HEARING PROTECTION WHEN OPERATING MACHINERY. Machinery noise can cause permanent hearing damage.

5. WEAR PROPER APPAREL. DO NOT wear loose clothing, gloves, neckties, rings, or jewelry which may get caught in moving parts. Wear protective hair covering to contain long hair and wear non-slip footwear.

6. NEVER OPERATE MACHINERY WHEN TIRED, OR UNDER THE INFLUENCE OF DRUGS OR ALCOHOL. Be mentally alert at all times when running machinery.

7. ONLY ALLOW TRAINED AND PROPERLY SUPERVISED PERSONNEL TO OPERATE MACHINERY. Make sure operation instructions are safe and clearly understood.

8. KEEP CHILDREN AND VISITORS AWAY. Keep all children and visitors a safe distance from the work area.

9. MAKE WORKSHOP CHILD PROOF. Use padlocks, master switches, and remove start switch keys.

10. NEVER LEAVE WHEN MACHINE IS RUNNING. Turn power OFF and allow all moving parts to come to a complete stop before leaving machine unattended.

11. DO NOT USE IN DANGEROUS ENVIRONMENTS. DO NOT use machinery in damp, wet locations, or where any flammable or noxious fumes may exist.

12. KEEP WORK AREA CLEAN AND WELL LIT. Clutter and dark shadows may cause accidents.

13. USE A GROUNDED EXTENSION CORD RATED FOR THE MACHINE AMPERAGE. Undersized cords overheat and lose power. Replace extension cords if they become damaged. DO NOT use extension cords for 220V machinery.

14. ALWAYS DISCONNECT FROM POWER SOURCE BEFORE SERVICING MACHINERY. Make sure switch is in OFF position before reconnecting.

15. MAINTAIN MACHINERY WITH CARE. Keep blades sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories.

16. MAKE SURE GUARDS ARE IN PLACE AND WORK CORRECTLY BEFORE USING MACHINERY.

17. REMOVE ADJUSTING KEYS AND WRENCHES. Make a habit of checking for keys and adjusting wrenches before turning machinery ON.

18. CHECK FOR DAMAGED PARTS BEFORE USING MACHINERY. Check for binding and alignment of parts, broken parts, part mounting, loose bolts, and any other conditions that may affect machine operation. Repair or replace damaged parts.

19. USE RECOMMENDED ACCESSORIES. Refer to the instruction manual for recommended accessories. The use of improper accessories may cause risk of injury.

20. DO NOT FORCE MACHINERY. Work at the speed for which the machine or accessory was designed.

21. SECURE WORKPIECE. Use clights or a vise to hold the workpiece when practical. A secured workpiece protects your hands and frees both hands to operate the machine.

22. DO NOT OVERREACH. Keep proper footing and balance at all times.

23. MANY MACHINES WILL EJECT THE WORKPIECE TOWARD THE OPERATOR. Know and avoid conditions that cause the workpiece to “kickback.”

24. ALWAYS LOCK MOBILE BASES (IF USED) BEFORE OPERATING MACHINERY.

25. BE AWARE THAT CERTAIN DUST MAY BE HAZARDOUS to the respiratory systems of people and animals, especially fine dust. Make sure you know the hazards associated with the type of dust you will be exposed to and always wear a respirator approved for that type of dust.

1. UNDERSTANDING CONTROLS. Make sure you understand the use and operation of all power feed controls.

2. SAFETY ACCESSORIES. Always wear your safety glasses when using the power feed.

3. WORK HOLDING. Before starting the power feed, be certain the workpiece has been properly clamped to the table. NEVER hold the workpiece against the table by hand during power feed operations.

4. SPINDLE SPEEDS. Select the spindle speed that is appropriate for the type of work and material. Allow the mill/drill to gain full speed before beginning a power feed operation.

5. POWER DISRUPTION. In the event of a local power outage when using the power feed, turn OFF all switches to avoid possible sudden start up once power is restored.

6. BE ATTENTIVE. DO NOT leave the area for any reason during any power feed operation.

7. DISCONNECT POWER. Unplug the power feed from power before starting any inspection, adjustment, or maintenance procedure.

8. MACHINE CARE AND MAINTENANCE. Never operate the power feed if the table is out of adjustment, is damaged, or has worn parts. Maintain your mill/drill in proper working condition. Perform routine inspections and maintenance promptly. Put away adjustment tools after use.

9. AVOIDING ENTANGLEMENT. Keep loose clothing articles such as sleeves, belts or jewelry items away from the table handwheels, and moving parts.

10. CLEAN-UP. DO NOT clear chips by hand, or blow off with compressed air. Use a brush, and never clear chips while the power feed is operating.

11. CUTTING TOOL INSPECTION. Inspect end mills for sharpness, chips, or cracks before beginning a power feed operation. Replace dull, chipped, or cracked cutting tools immediately. Handle new cutting tools with care. Leading edges are very sharp and can cause lacerations.

12. EXPERIENCING DIFFICULTIES. If at any time you are experiencing difficulties performing the intended operation, stop using the machine.

The SHOP FOX D3694 is wired for 110V operation. The power supply circuit used for this machine MUST be grounded and rated for the amperage given below. The electrical cord supplied with this machine comes with a grounding pin. If your outlet does not accommodate a ground pin, have it replaced by a qualified electrician.

Using an extension cord is not recommended; however, if you have no alternative, use the following guidelines:

• Use a cord rated for Standard Service (S).

• Do not use an extension cord longer than 50 feet.

• Ensure that the cord has a ground wire and pin.

• Don’t remove the ground pin to accommodate a two-prong 110V wall receptacle.

• Use the gauge size listed in the electrical specifications (14 Gauge minimum).

The following items are needed to complete the setup process, but are not included with your machine:

• Wrench 10mm (Qty: 1)

• Center Punch (Qty: 1)

• Power Drill (Qty: 1)

• Drill Bit #25 (Qty: 1)

• Bottoming Tap #10-24 (Qty: 1)

• Flat Head Screws #10-24 x 1/2″ (Qty: 2)

• Hex Wrench 3mm (Qty: 1)

• Hex Wrench 4mm (Qty: 1)

• Hex Wrench 5mm (Qty: 1)

• Phillips Screwdriver #1 (Qty: 1)

• Phillips Screwdriver #2 (Qty: 1)

• Flat Tip Screwdriver #2 (Qty: 1)

• Flat Metal File 10″ (Qty: 1)

• Small Hammer (Qty: 1)

• Dowel Punch 1/8″ (Qty: 1)

• Medium Workbench Vise (Qty: 1)

A. Limit Switch Assembly (Qty: 1)

B. Power Feed Unit (Qty: 1)

C. Power Cord (Qty: 1)

D. Cap Screws M6-1 x 16 (Power Feed Mounting) (Qty: 2)

E. Limit Blocks (L/R) for 10mm T-Slot Size (Qty: 2)

F. Limit Blocks (L/R) for 8mm T-Slot Size (Qty: 2)

G. Limit Blocks (L/R) for 6mm T-Slot Size (Qty: 2)

1. DISCONNECT THE MILL FROM POWER!

2. Loosen the gib screw lock nuts, and adjust the X-axis table gib screws, so the table moves with slight resistance as felt when rotating the handwheel. Make adjustments on all four locations equally and in small increments.

3. When properly adjusted, tighten the lock nuts.

4. Locate the X-axis leadscrew half-nut.

5. Adjust both half-nut cap screws until the handwheel has approximately 0.003″ backlash, as shown by the dial.

6. Use a #1 Phillips screwdriver to remove the four flat head screws from both ends of the power feed.

7. Carefully slide the motor and mounting plate out from the housing a few inches.

8. Carefully slide the circuit board and vent cover out from the housing a few inches.

9. Using a standard screwdriver, pry off the leadscrew dust cap.

10. Using a 5mm hex wrench, remove the two end plate retaining cap screws.

11. Thread the cap screws into the power feed mounting holes and, in an alternating fashion, tighten the screws to remove the table end plate.

12. On both tapered pins, measure and record the amount of pin protrusion from the face of the end plate.

13. Using a hammer, and working from the inside out, drive both wedge pins from the end plate. DO NOT hammer the protruding pins flush with the end plate cover, as the pins are tapered and WILL crack the end plate.

14. Using a file or bench grinder, shorten the pins, so they are recessed slightly below the face when reinstalled.

15. Using soft jaws, secure the end plate in a vise with the painted surface facing up.

16. Using a 10″ or longer flat metal file, remove any high spots in the paint to give the table end cap and the power feed a flat mating surface. Ensure the surface is flat.

17. Using a standard screwdriver, scrape away any paint from the bushing bore so the bushing sits properly without binding.

18. Reinstall the end plate, and drive the tapered pins in, so they are slightly recessed in the end plate face.

19. Rotate the power feed drive tang so it aligns with the leadscrew slot.

20. Place the power feed motor onto the end plate, and secure it with the two M6-1 x 16 mm cap screws.

21. Carefully slide the circuit board and vent cover back into the power feed housing, but do not install the four mounting screws yet. The circuit board and vent cover must be left loose to insert the motor without pinching wires.

22. Being careful not to crush or bind wires, slide the power feed housing onto the end of the motor. You may have to reposition the circuit board and vent cover to avoid interference.

23. Secure the vent cover and the mounting plate to the power feed housing with the eight flat head screws previously removed in Step 6.

24. Install the left and right limit blocks into the table slot. Position the stops so the table can travel an additional 10mm before the leadscrew runs out of thread. This prevents a damaging hard stop.

25. Using a Phillips screwdriver, remove the three mounting screws that secure the limit switch to its mounting plate.

26. Install the limit switch mounting plate on the side of the milling table base so the limit switch stop pins are horizontally aligned with the stop pins. Ensure there is enough gap between the limit switch housing and the gib screw lock nut.

27. When the mounting plate is properly positioned, center punch one mounting hole.

28. Using an electric drill, drill one #25 mounting hole 1/2″ deep into the table base.

29. Using a #10-24 bottoming tap, cut threads into the hole.

30. Secure the limit switch mounting plate to the table base with one #10-24 x 1/2″ flat head screw.

31. Center punch the other hole and drill, tap, and install the remaining screw.

32. Install the limit switch to the mounting plate with the three previously removed screws.

33. Secure the power and limit switch power cables away from the path of the moving table and handwheels.

1. Read the entire instruction manual first and understand the SAFETY section.

2. Manually crank the X-axis handwheel to position the table to the far right and then far left, just until the limit block depresses the motor stop limit switch pin. You MUST verify that the stops depress the switch pin before the table reaches its end of travel to prevent damage.

3. Park the table in the far left position.

4. Rotate the Feed Speed Dial counterclockwise until you hear it click to OFF, and move the Feed Direction Lever to the center OFF position.

5. Connect the power feed to power. The green Power Light will illuminate.

6. Move the Feed Direction Lever to the right position. Before the table reaches the end of its travel, do the following:

A. Rotate the Feed Speed Dial clockwise slowly until the table begins to move right. Vary the knob position to see the feed speed change.

B. Push and hold the Rapid Feed Button momentarily to test for rapid table movement.

C. Push the limit switch; the power feeder should stop and the fault light will illuminate.

7. Rotate the Feed Speed Dial counterclockwise until it clicks to OFF again. Move the Feed Direction Lever to the left position, and the fault light will go out.

8. Repeat Step 6 to test the left-hand table feed.

• When milling, it is best to have the spindle recessed into the headstock as much as possible and locked to help prevent deflection and tool chatter.

• When using the power feed, attempt to stay with conventional milling practices where the chips are expelled against the direction of table feed rather than with the direction of table feed. Milling with the direction of table feed causes a climb cut where the cutter will often chatter or grab the workpiece and cause tool breakage.

• When using the power feed, avoid adjusting the feed rate dial or the spindle speed during milling operations. A sudden change in feed rate or spindle RPM can cause the cutter to chatter or grab the workpiece and cause tool breakage.

• Typically during power-fed milling operations, if chips are blue colored or the tool is overheating, reduce feed rate and increase spindle RPM. If chips are very fine and powdery, decrease spindle RPM or increase feed rate to prevent the tool from dulling.

Daily Check:

• Loose mounting screws.

• Table, lead screws, and ways are clean and lubricated.

• Worn or damaged wires.

• Power limit blocks are secured and properly adjusted to prevent a table crash or “hard stops.”

Monthly Check:

• Gibs are adjusted properly.

• Oil power limit block pins.

Annual or Biannual Check:

• Lubricate headstock lead screw and gears.

Lubrication:

Once a day before and after use, oil the power-feed ball oiler located where the power feed is mounted to the table. Once a week, lubricate the power limit block pins and springs. You can use any standard 30W motor oil, illuminate machine oil, or the type of oil you are currently using to lubricate your mill.

Cleaning:

Vacuum away metal chips, and wipe off the remaining dust or oil with a dry cloth. Protect the unpainted cast iron surfaces on the table stops by wiping them clean after every use to prevent metal shavings from rusting metal surfaces. Keep tables rust-free with regular applications of a quality metal protectant.

You may have to replace the brush set if the unit loses RPM or becomes noisy. The tools needed are a #3 Standard Screwdriver and Needle Nose Pliers.

1. DISCONNECT MACHINE FROM POWER!

2. Unscrew the power feed top dust cap.

3. Unscrew the brush retaining cap, use needle nose pliers to replace the brush, and reinstall the caps.

4. Replace the second brush at the underside of the power feed.

1. SHOCK HAZARD. Working on wiring that is connected to a power source is extremely dangerous. Disconnect the power from the machine before servicing electrical components.

2. WIRE CONNECTIONS. All connections must be tight to prevent wires from loosening during machine operation. Double-check all wires disconnected or connected during any wiring task to ensure tight connections.

3. MODIFICATIONS. Using aftermarket parts or modifying the wiring beyond what is shown in the diagram may lead to unpredictable results, including serious injury or fire.

4. MOTOR WIRING. The motor wiring shown in diagrams may not match your machine. Always use the wiring diagram inside the motor junction box.

5. QUALIFIED ELECTRICIAN. Due to the inherent hazards of electricity, only a qualified electrician should perform wiring tasks on this machine.

6. WIRE/COMPONENT DAMAGE. Damaged wires or components increase risk. If you notice any damaged wires or components while performing a wiring task, replace them before completing the task.

7. CIRCUIT REQUIREMENTS. You MUST follow the electrical requirements when connecting your machine to a power source.

First, ensure power is disconnected and moving parts have stopped. The possible causes and corrective actions are:

1. Power cord is faulty. Check all electrical connections, and repair or replace wires or connections as required.

2. Power light is not lit and fuse has blown. Correct the short and replace the fuse.

3. Fault light is lit. Reset the power feed by moving the feed direction lever to the center position and turning the feed speed dial to 0.

4. Limit switch is stuck open. Replace the limit switch assembly.

5. Motor brush is at fault. Replace the brush set.

6. Feed direction switch is at fault. Replace the switch.

7. Feed speed rheostat is at fault. Replace the rheostat.

8. Circuit board is at fault. Replace the circuit board.

9. Gearbox is at fault. Replace the motor and gearbox assembly.

10. Motor is at fault. Replace the motor and gearbox assembly.

First, ensure power is disconnected and moving parts have stopped. The possible causes and corrective actions are:

1. Table gib is binding table. Clean, lubricate, and adjust the table gib.

2. Leadscrew is binding. Clean, lubricate, and adjust the leadscrew.

3. Motor brush is at fault. Replace the brush set.

4. Feed speed rheostat is at fault. Replace the switch.

5. Circuit board is at fault. Replace the circuit board.

6. Gearbox is at fault. Replace the motor and gearbox assembly.

7. Motor is at fault. Replace the motor and gearbox assembly.

First, ensure power is disconnected and moving parts have stopped. The possible causes and corrective actions are:

1. Wiring at fault. Tighten the loose connection, or repair wiring.

2. Feed direction switch at fault. Replace the feed direction switch.

3. Limit Switch is at fault. Replace the limit switch assembly.

4. Circuit board is at fault. Replace the circuit board.

First, ensure power is disconnected and moving parts have stopped. The possible causes and corrective actions are:

1. Table feed rate or cutter speed at fault. Slow the feed rate, and recalculate the cutter speed.

2. Cutter at fault. Sharpen or replace the cutter, or use the correct cutter.

3. Loose table. Adjust gibs, lead screws, and tighten the Y-axis gib lock.

4. Loose headstock. Tighten Z-axis gib and spindle locks.

5. Power feed gearbox at fault. Replace the motor and gearbox assembly.

The following milling accessories may be available:

• The Shop Fox D3695 Horizontal Milling Table: For use with the Model M1111 mill/drill 90° tilting headstock feature, providing correct clearance for side-milling operations.

• The Shop Fox D3693 Worktable with Angle: A high-quality tilting worktable to support your workpiece at an array of angles.

• The Shop Fox M1076 4″ Rotary Table: A rotary table for model makers and smaller precision work, which comes with a clamping kit.