Sherline 5000 Mill Assembly Instructions

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SHERLINE SERVICE POLICY

Sherline’s policy regarding customer service is simple: CUSTOMER SATISFACTION!

Because products manufactured by Sherline are completely produced in our Vista, California plant, we offer

fast and reasonably priced service. All we ask when you pack the items for shipping is to use common sense,

individually protecting items from one another during shipping. Ship by UPS whenever possible. If you have

attempted a repair and then decide to return the item it is not necessary to reassemble the machine. If you

have lost a part, don’t worry, we’ll still get it looking great for you and return it via UPS*. Equipment will be

returned C.O.D. if it is not warranty work.

Cleaning the returned items thoroughly before you ship them will save time and money.

*If merchandise is received damaged by UPS, keep the original shipping carton and contact your local UPS office.

HOW TO ORDER REPLACEMENT PARTS

The model number of your machine will be found on the nameplate attached to the top or side of the

headstock. The serial number is located on the back of the headstock. Always mention the model number

when requesting service or repair parts for your machine or accessories.

Replacement parts may be ordered from the factory or from any Sherline dealer. The most expeditious way

to order parts is directly from the factory by phone. Sherline’s office hours are 8 A.M. to 4 P.M. (PST or

PDT) Monday through Friday. Orders received before 12 noon (Pacific Standard or Daylight Time) will be

shipped the same day. We accept payment by Visa, MasterCard, Discover or American Express.

Parts orders:

Toll free order line: (USA)1-800-541-0735

International or Technical Assistance: 1-760-727-5857 • Fax: 760-727-7857

FULL ONE YEAR WARRANTY

on Sherline’s 3.5" Metal Lathe, Vertical Milling Machine and Accessories

If within one year from the date of purchase a new* Sherline power tool or accessory fails due to a defect in

material or workmanship, Sherline will repair it free of charge. In addition, it has always been our policy to

replace at no cost all parts, regardless of age, which are determined to have been incorrectly manufactured

or assembled and have failed due to this cause rather than because of improper use or excessive wear

caused by continuous use in a production environment. In cases such as this, Sherline will inspect the machine

or part and will be the sole judge of the merit of the claim. Freight charges for returning a machine are not

covered. Merchandise which has been abused or misused is not subject to warranty protection.

Warranty service is available by simply returning the machine, defective assembly or part to:

Sherline Products, Inc., 3235 Executive Ridge, Vista, CA 92083-8527

Please write, fax, call or e-mail to let us know that you are retuning a part and to receive a return

authroization number. This will speed up the warranty process. (E-mail is sherline@sherline.com)

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

*NOTE: Only new machines purchased directly from Sherline or from an Authorized Sherline dealer are covered under this warranty.

Machines purchased from a non-authorized source are considered "used" and are not subject to warranty even if they appear to be new. If

you are in doubt about the status of a dealer or are suspicious about an offer, you should confirm the dealer's status by checking our dealer

listing at www.sherline.com/dealers.htm or by calling (800) 541-0735 for confirmation. Proof of date of purchase and dealer name may be

required for service under this warranty.

To take a look at the newest offerings from Sherline

Products, look in on our Internet site. You will find a

complete list of all our accessories as well as the fully

illustrated instructions for each one. Learn how a part

is used before deciding to buy, or print out the directions

for your later use. There is also a U.S. and worldwide

dealer listing, replacement parts listing, current price

list as well as a “Resources” page with hot links to

many other items of interest to miniature machinists.

There is even a “factory tour” in photos. You have a

wealth of free information at your fingertips. Our

address is: www.sherline.com. You may now place

your order by e-mail at sherline@sherline.com or order

on-line 24 hours a day at www.sherlinedirect.com.

SHERLINE IS ON THE INTERNET

Summary of content (48 pages)

PAGE 1
FULL ONE YEAR WARRANTY on Sherline’s 3.5" Metal Lathe, Vertical Milling Machine and Accessories If within one year from the date of purchase a new* Sherline power tool or accessory fails due to a defect in material or workmanship, Sherline will repair it free of charge.
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TABLE OF CONTENTS Inserted tip carbide tools . . . . . . . . . . . . . . . . . . . . . 24 Turning speeds and feed rates, general rules . . . . . . 24 Accessories for the lathe 3-Jaw, 4-jaw and drill chucks . . . . . . . . . . . . . . . . . . 25 Thread-cutting attachment . . . . . . . . . . . . . . . . . . . . 25 Steady rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Additional lathe accessories . . . . . . . . . . . . . . . . . 26 3-JAW CHUCK OPERATION. . . . . . . . . . . . . . . . .
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SAFETY RULES FOR POWER TOOLS 1. KNOW YOUR POWER TOOL—Read the owner’s manual carefully. Learn its application and limitations as well as the specific potential hazards peculiar to this tool. 2. GROUND ALL TOOLS—If a tool is equipped with a threeprong plug, it should be plugged into a three-hole receptacle. If an adapter is used to accommodate a twoprong receptacle, the adapter wire must be attached to a KNOWN GROUND. Never remove the third prong. (See Figure 1 in right-hand column.) 3.
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AN INTRODUCTION TO THE WORLD OF MINIATURE MACHINING Getting answers to your questions about machining Over the years we have found that the majority of our customers are both highly intelligent and skilled craftsmen. Often they are also new to machining. The instructions we have included in this book, while far more extensive than anything included with other machine tools, even ones costing thousands of dollars, still only scratch the surface when it comes to machining.
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THE CUSTOMER’S RESPONSIBILITIES Always use care when operating the lathe and mill. Follow the safety rules for power tools on page 3. Turn off the motor before attempting adjustments or maintenance. (Do not simply turn the speed control down to zero RPM but leave the motor switch on.) Be sure the work piece is firmly supported on the lathe or mill. Accessories should be mounted and operated following instructions carefully. Keep your machine clean, lubricated and adjusted as instructed.
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FIGURE 3—Installing the crosslide table onto the saddle also the factory machines that we use to produce them. Several manufacturers now offer it in small grease gun canisters that are available at hardware and auto part stores. It offers smoother action than conventional grease when used on sliding parts, and we highly recommend it. INITIAL ASSEMBLY OF A NEW MACHINE Your new lathe or mill will come packed in a box with some items disassembled for shipping purposes.
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CHECK THE TIGHTNESS OF ALL BOLTS Vibration in shipping can cause some bolts or screws to loosen up. Before using your new machine, check the tightness of all fasteners. It is also a good idea to check tightness periodically when using the machine, as vibration from operation may cause some fasteners to loosen up. included with the P/N 8100 digital readout to install the encoder housing and handwheel unit.
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A in the speed control housing and into the nut in the mounting plate. Tighten enough to hold it in place. Do not overtighten. NOTE: If you machine a lot of wood or brass, you may want to purchase and install a switch cover (P/N 3015) to keep the fine dust out of the power switch. The wood dust can gum up the switch causing intermittent operation. Brass dust can short out the switch or cause a risk of electric shock to the operator.
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HIGH SPEED SPINDLE OPERATION A special pulley set is available that turns the spindle at up to its maximum rated capacity of 10,000 RPM. See P/N 4335. OPERATION OF THE MOTOR AND ELECTRONIC SPEED CONTROL The lathe is supplied with an electronic speed control that produces a comprehensive range of speeds suitable for all operations. Special circuitry designed into the DC motor speed control automatically compensates for speed changes due to increased load.
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NOTE: Alignment keys are fitted to each machine. If you have more than one machine or component that uses an alignment key, try not to mix them up. Removing the headstock alignment key permits the headstock to be mounted in positions other than square. This allows you to mill parts at an angle or turn tapers on the lathe. When using the lathe or mill without the alignment key, keep cutting loads light.
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SADDLE BED belt guard housing. Loosen the two nuts that hold the motor to the motor mounting bracket and take the tension off the belt. With your finger, push the belt off the larger diameter groove of the pulley and into the smaller one. (Depending on which way you are changing it, this could be either the motor or spindle pulley.) Then move the belt to the larger diameter groove on the other pulley, and rotate the headstock by hand to get it to seat.
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Want to see some projects built by other Sherline machinists? Visit www.sherline.com/workshop.htm. If a handwheel has been removed, when reinstalling it, make sure it is pushed up tightly against its thrust collar before tightening the set screw. Push the appropriate table or saddle toward the handwheel to remove any excess play before tightening. For the mill Z-axis, lift up on the headstock to remove play.
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Questions? See our “Frequently asked questions” section on the web site: www.sherline.com/faq.htm. would dramatically increase the price. We try to give a customer what we consider "the most bang for the buck." Why aren't there alignment pins to square up the machine? If you are a novice to machining, you probably believe a machine should be designed so that a couple of pins could be dropped into holes, squaring up the machine and eliminating this whole process.
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WHEN SQUARE, SCRIBE ZERO REFERENCE MARK HERE FIGURE 18—Squaring up the ram parallel to the Yaxis on the 2000-series mill. The indicator can be held with a chuck on the table or a mill vise as shown here. When square, tighten the nut on top of the column. 5000/ 5400-series mills can be adjusted slightly by loosening the two bolts that hold the column base in place, twisting the column slightly and retightening the bolts.
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ADJUST FORE/AFT MOVEMENT WITH CENTER ADJUSTMENT SCREW ON ALIGNMENT BLOCK LOCK ADJUSTMENT IN PLACE WITH 11/16" FLANGE NUT FIGURE 20—Squaring the fore and aft pivot movement of the column with the Y-axis. (See the hint in the section on squaring the X-axis above for a way to keep the tip of the indicator from dropping into the T-slots.) would not remain at “0” but would now be a negative reading.
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HEADSTOCK PIVOTS ON SADDLE PIN. EVEN WITH ALIGNMENT KEY IN PLACE, SLIGHT ADJUSTMENT CAN BE MADE TO GET HEADSTOCK PERFECTLY SQUARE.. FIGURE 21—Fine tuning the headstock rotation alignment with a machinist's square and dial indicator. The headstock pivots on the saddle pin. Even with the alignment key in place, slight adjustment can be made to get the headstock perfectly square. any error, but in most cases there will be a small amount.
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FEED lever is standard on all non-CNC-ready mills and vertical milling columns as of that date. This lever is located on the Z-axis leadscrew behind the saddle. When turned to the full clockwise position the saddle will move freely. A springloaded ball locates in a detent in the bottom of the lever to hold it in this position. To lock the saddle in position, move the lever to the full counterclockwise position. This locks the lever against the saddle nut which prevents the leadscrew from turning.
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to get to the end of the cut in the same amount of time. The chip is twice as thick, so the feed is GREATER at lower RPM if the feed RATE stays constant.) When a tool chatters, it gets dull faster, because it must keep cutting through the previously machined surface that has been “work hardened” by machining. As you can imagine, there are limits to how much you can increase feed rate, so the answer lies in adjusting both speed and feed to achieve the proper cut.
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SPEED CONTROL ASSEMBLY SPEED CONTROL KNOB ON/OFF SWITCH TAILSTOCK DRILL CHUCK HEADSTOCK DC MOTOR TAILSTOCK SPINDLE TOOL POST 3-JAW CHUCK TAILSTOCK SPINDLE LOCK CROSSLIDE TAILSTOCK SADDLE TAILSTOCK FEED HANDWHEEL HEADSTOCK SPINDLE “V” BELT TAILSTOCK LOCKING SCREW BED 2-SPEED STEPPED PULLEY HEADSTOCK LOCKING SCREW LEAD SCREW HANDWHEEL TAILSTOCK GIB GIB TAILSTOCK LATHE DOG FACEPLATE NO.
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FIGURE 27—Holding a square work piece in a 4-jaw chuck FIGURE 29—Tailstock center drilling. The work turns while the drill is held stationary in the tailstock REMOVING TOOLS FROM THE MORSE TAPERED SPINDLES Accessories held in the headstock spindle use a Morse #1 taper and can be removed with the use of a knockout rod (not supplied) approximately 3/8" in diameter and 6" long.
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FIGURE 30—Headstock drilling. The drill turns in the headstock spindle while the work is held stationary. REAMING Twist drills will generally not drill perfectly accurate sizes, and very small boring tools are not satisfactory in deep holes because of their flexibility. Therefore, reaming is used for holes requiring accuracy within .0005" (.013 mm). Reamers are available in any standard size, but they are rather expensive and are generally not purchased to do one-of-a-kind type work.
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Remember that heavy cuts and rapid feed will cause greater strain on the chuck and lathe. This may induce “spring” or binding of work and tools that can produce a poor finish. NOTE: Because of the importance of a sharp and properly ground tool to the cutting process, Sherline has prepared a special instruction sheet on Grinding Your Own Lathe Tools. There are a few tips that can make the process a simple one.
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finish due to the small length of tool edge in contact with the work. This ridging becomes more pronounced with rapid feed. To provide a smooth finish, the sharp cutting point may be slightly rounded with an oilstone, taking care to preserve the side clearance underneath this corner. This type of tool should not be advanced directly endwise into the work. The depth of cut is set while the tool is clear of the end of the work.
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P/N 7600 TOOL POST FOR 3/8” INSERT HOLDERS AND 3/8” ROUND BORING TOOLS BORING TOOLS The use of this tool requires the existence of a drilled or cored hole, or it may be used to enlarge the bore of a tube. The work must be mounted in a chuck or on a faceplate and the boring tool set as shown in Figure 34. Note the clearance behind the cutting point as shown in Figure 38 below.
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GUIDE TO APPROXIMATE TURNING SPEEDS Material Cut Speed 1/4" (6mm)1/2" (13mm)1" (25mm) S.F.M. Diameter Diameter Diameter Stainless, 303 67 1000 RPM 500 RPM 250 RPM Stainless, 304 50 800 400 200 Stainless, 316 47 700 350 175 Steel, 12L14 174 2600 1300 650 Steel, 1018 87 1300 650 300 Steel, 4130 82 1250 650 300 Gray Cast Iron 57 900 450 220 Aluminum, 7075 400 2800 2800 1400 Aluminum, 6061 375 2800 2800 1400 Aluminum, 2024 268 2800 2000 1000 Brass 400 2800 2800 1400 P/N 1040 3.
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“single pointing” a thread. When the spindle turns, the saddle moves. If they were geared one-to-one, the cutting tool would cut a pitch that would be the same as the leadscrew. On Sherline’s inch machines, this would be 20 threads per inch. If the leadscrew turns 180° while the spindle turns 360° (by using a 20-tooth to a 40-tooth gear reduction) we would cut 40 TPI. Note that threads can be applied to any diameter stock. HANDWHEEL DRIVES SPINDLE SHAFT (HANDWHEEL REMOVED FOR CLARITY.
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1292 Tailstock riser block—Raises tailstock 1.25" (31.7 mm) to align it with headstock when using the P/N 1291 riser block. 2049 Spindle handwheel— Steel handwheel mounts on the end of the spindle shaft and allows the operator to quickly and safely stop a rotating spindle with his hand. It also makes it easy to hand index the spindle when working on a part. 2085 (WW) and 2086 (8mm) collet adapters—Held in P/N 1203 adjustable tool holder above (not included), collet adapters allow you to use WW or 8.
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3-JAW CHUCK OPERATION AND MAINTENANCE jaws are removed, they can be easily identified by the location of the teeth in relation to the end of the jaws (See Figures 45 and 46). To maintain chuck accuracy, the 2nd jaw must always be inserted in the same slot even when the jaws are reversed. This slot is identified by the laser engraved letter “B” next to the slot. Always insert the jaws in the order and location shown on the drawings.
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VERTICAL MILLING MACHINE OPERATION CAUTION! READ ALL OPERATING INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING ANY MACHINING OPERATIONS. NOTE: See pages 4 through 18 for setup, lubrication and general machining instructions. Read Safety Rules for Power Tools on page 3 before operating machine.
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HEADSTOCK ALIGNMENT KEY VERTICAL FEED HANDWHEEL (Z-AXIS) DC MOTOR 2-SPEED STEPPED PULLEY SPEED CONTROL ASSEMBLY “V” DRIVE BELT VARIABLE SPEED CONTROL KNOB COLUMN SADDLE LOCK (BEHIND SADDLE ON LEADSCREW) ON/OFF SWITCH HEADSTOCK SPACER BLOCK HEADSTOCK HEADSTOCK LOCKING SET SCREW Z-AXIS GIB SPINDLE DRILL CHUCK TABLE FEED HANDWHEEL (X-AXIS) TABLE Z-AXIS COLUMN BED COLUMN BASE SADDLE TABLE LOCK ASSEMBLY Y-AXIS ANTI-BACKLASH NUT AND LOCK TABLE FEED HANDWHEEL (Y-AXIS) “T” SLOTS (2) X-AXIS STOP SCREW
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loose after machining. A mill tooling plate (P/N 3560) is a very useful fixture for holding parts. It has a number of holes predrilled for holding clamps, and additional holes can be drilled and tapped as needed. It also provides additional stiffness and protection for your mill table.
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CAUTION! Because the tool spins on a mill, hot chips can be thrown much farther than when using a lathe. Safety glasses and proper clothing are a must for all milling operations. order quantities and high “cutting charge” fees that make it impractical to purchase small amounts from them. However, there are now a number of suppliers that cater to the hobby market. They have complete catalogs of the materials most commonly used by hobbyists, and you can order as much or as little as you need.
PAGE 33
CLIMB MILLING ADVANTAGES AND DRAWBACKS Though you will almost always use conventional milling, climb milling can create a better finish in two ways. First, the lightest part of the cut is at the end of the cut. Second, the chips are tossed from the cutting area and do not affect the finish. The major problem with machining in this direction is that the cutter may actually do just that—climb up on the part and break. Also, when a climb cut is first started, the work has to be pushed into the cutter.
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placement of the bed by running an indicator on the square as the headstock is raised and lowered. (See Figure 21, page 16.) The same method can be used to check alignment of the column bed to ensure it is square with the Y-axis. To correct any error (which should be small), place a shim between the column block and the mill base. LOCATING THE EDGE OF A PART IN RELATION TO THE SPINDLE There are two quick methods of “picking up an edge” of a part on a mill.
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CUTTING SPEEDS FOR MILLING SPEED ADJUSTMENT CHART SPINDLE RPM = 3.82 x S.F.M. D S.F.M. = The rated Surface Feet per Minute for milling. For drilling, use 60% of the rated surface feet. RPM = The rated spindle speed in Revolutions Per Minute D= The Diameter of work in inches FIGURE 59—Formula for adjusting spindle speed for cutting a given diameter. NOTE: To estimate RPM, remember that the speed range of your vertical mill is from 0 to 2800 RPM.
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END MILLS (Slot and side milling) MATERIAL FIGURE 62—Mill column saddle lock CUT SPEED (S.F.M.)1/8” DIA. 1/4” DIA. 3/8” DIA.
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P/N 7620 FLY CUTTER WITH CARBIDE INSERT P/N 3052 FLY CUTTER USES A 1/4" SQUARE HSS OR BRAZED CARBBIDE CUTTING TOOL FIGURE 65—Mill collet set BORING HEAD (P/N 3054/3049) AND BORING TOOLS The main purpose of the boring head is to eliminate the need for a large inventory of drills and reamers. A small milling machine would not have the power or rigidity to turn a one-inch diameter drill even if one could be obtained that would fit.
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diameter of the drill without clearing the chips and adding coolant. For example: To drill a 1/8" diameter hole 1" deep: 1st Pass: 2 times diameter or 1/4" 2nd Pass: 1 times diameter or 1/8" 3rd Pass: 1 times diameter or 1/8" Etc. mill vise is a rotating base (P/N 3570) that greatly adds to the versatility of this basic machining accessory.
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the work. (Note: The greater versatility and capacity of the 2000-series 8-direction mill eliminate the need for this accessory on those mills.) The black anodized mounting plate is predrilled to mount the base and column in several possible locations. Alignment bars and a selection of appropriate bolts are included to make it easy to accurately relocate the column. Rubber feet insulate the table for quiet, vibration-free operation. (Note: The column base should be shortened by 2" for best operation.
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FIGURE 78—The P/N 5650 (inch) or P/N 5660 (metric) upgrade includes everything you need to bring your existing Sherline mill up to the 8direction capacity of the Model 2000 mill. Other sizes are available individually, see the “Cutting tools price list.” 3200 Indexing Attachment—Cut gears of any number of teeth or drill precise hole patterns. The indexing head and tailstock are mounted on a 12" dovetailed bed. Includes a gear cutter holder and cutting tool blank.
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5329—Shop Secrets Video–Measuring Tools, by Mike Rehmus. A great introduction to the proper use of measuring tools for machining. 2 hours, VHS fits 5000-series mills, while P/N 5151 is sized for 2000series mills. 8100 (8160) Mill Digital Readout—3-axis digital readout can be added to any existing mill or ordered factory installed on any new mill. Reads to .0005" or .01 mm. Resets to zero with the push of a button. Also reads out spindle RPM at all times. See photo on page 35.
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SHERLINE LATHE EXPLODED VIEW AND PART NUMBER LISTING NOTE: Where different, Inch part number is given first, followed by Metric part number. 41130 30220 40510 90080 90060 2-PART LEADSCREW END DETAIL 40660 30230 43200 (Label) 43110 43170 43460 40520 43150 43160 43140 *LEADSCREW BODY PART NUMBERS Tailstock Feed Screw Body—40221 (41221) Crosslide Slide Screw Body—44211 (44221) 43170 40620 40630 (UK) 40640 (Eur.
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SHERLINE VERTICAL MILLING MACHINES EXPLODED VIEW AND PART NUMBER LISTING NOTE: Where different, Inch part number is given first, followed by Metric part number. 1297 45013 34220 41080 34410 40620 (US) 40630 (UK) 40640 (Euro.
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SHERLINE MODEL 2000 MILL COLUMN EXPLODED VIEW AND PART NUMBER LISTING SADDLE NUT ASSEMBLY 40177 (Inch), 41177 (Metric) 1/8" BALL, P/N 40178 SPRING, P/N 22630 40690 40176 SADDLE NUT BODY P/N 40179 (Inch) P/N 41179 (Metric) 56230 56200 40175 (Inch) 41175 (Metric) 50220 40330 40670 40340 56400 56350 45011 (Inch) 45161 (Metric) 56230 56220 35160 56550 56330 (Inch) 56331 (Metric) 56450 50211 40690 56440 56110 40670 35170 56770 56130 56700 56210 56470 NOTE For part numbers of table, column bed a
PAGE 45
PART NUMBERS AND DESCRIPTIONS, SHERLINE LATHES AND MILLS KEY TO MATERIALS: A=Aluminum, B=Brass, C=Composite, DC=Die Cast, P=Plastic, U=Urethane, S=Steel PART NO.
PAGE 46
MACHINING BASICS—USING THE HANDWHEELS P keep a smooth, continuous feed going. On small machines, the handwheel is turned by its outer knurled surface using the thumb and a finger of one hand. Then, as that hand is released, the thumb and finger of the other hand pick up the rotation. Using the handle on the handwheel can introduce pushing and pulling motions that can adversely affect the finish. (See Figure 83.
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Sherline’s owner, Joe Martin, has put together the ultimate book for the Sherline machinist... This book gives you not just the “hows,” but also the “whys” of machining The perfect “next step” beyond this instruction book Right now you are holding one of the most complete instruction booklets ever given away with any machine tool, regardless of size or price. However, as complete as it is, most new machinists will have more questions than can be answered in a basic instruction guide.
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P/N 5326 SHERLINE PRODUCTS INCORPORATED 1974 MINIATURE MACHINE TOOLS ASSEMBLY AND INSTRUCTION GUIDE FIFTH EDITION ©2003, Sherline Products Inc.