Escomatic D2 / D4 Setup Operator Training System

The following MasterTask lesson outline indicates the tasks needed to act as a machinist on Escomatic automatic screw machines. Because of the performance-based approach to training utilized within MasterTask systems, the outline below indicates what a trainee will be able to DO after completing each part of a lesson. Some of these tasks require the trainee to explain how something works to insure they have the required understanding of the processes and are not simply memorizing procedures. All of the tasks listed will be a part of the Performance Test within each lesson. To learn more about these tests and the training process itself, review The MasterTask Concept and Course Materials.

LESSON 1: BASIC MACHINE COMPONENTS

The purpose of this lesson is to show the location of main operating groups of the Model D2 and D4 Escomatics. The basic operation of each group will be explained. After completing this lesson, the Operator will be able to locate, identify, and explain the purpose of:

1. Stock Straightener Cam

2. Stock Clamping Jaws and Cam

3. Feed Rolls and Feed System

4. D2 Counter Collet and Cam

5. D4 Drill Drum Turret and Cams

6. Tool Head and Stock Guide Bushing

7. Belt, Pulley, and Motor Drives

LESSON 2: BASIC CONTROLS AND OPERATION

The purpose of this lesson is to familiarize the Operator with the basic operator controls on the Model D2 and D4. After completing this lesson, the Operator will be able to locate, identify, and explain the purpose for and operate each basic control.

1. Location and Description of Operator Controls and Levers

2. Stock Clamp Lever for Feed System

3. Head Locking Lever for the Tool Head

4. Camshaft Start/Stop Lever

5. Hand Crank Wheel

6. Procedures for Starting and Stopping the Machine

7. Procedures for Raising and Lowering the D2 Counter Collet and D4 Drill Turret

LESSON 3: MACHINE LUBRICATION

The purpose of this lesson is to teach the basic procedure of machine lubrication. After completing this lesson, the Operator will be able to adjust and fill:

1. Automatic Drip Oilers

2. Ball Type Oilers

3. Feed System Hydraulic Unit, Coolant Reservoir, Drill Turret Command Unit, and Main Gear Box

4. Operate Coolant Valves

5. Clean Coolant Filters

6. Check Wire Cleaner Operation

LESSON 4: COIL RESTOCKING

The purpose of this lesson is to instruct the Operator on restocking the Model D2 and D4 Escomatics with coil stock. After completing this lesson, the Operator will be able to restock the machine.

1. Stock Dereeler Operation and Restocking

2. Removal of Stock Remnant

3. Manual Stock Straightening

4. Inserting Stock Through the Machine

LESSON 5: SETTING UP PULLEYS AND GEARS

The purpose of this lesson is to instruct the Operator on the basic information for reading and using production rate charts. The lesson will also show the Operator how to use and read pulley and belt charts, along with basic procedures for changing and adjusting drive system components. After completing this material, the Operator will be able to:

1. Read Production Rate Charts

2. Read Belt and Pulley Charts

3. Change Belts and Pulleys for Tool Head Speed, Stock Straightener Rotor Speed, Drill Spindle Speed

4. Change Belt and Pulleys and Gears for Production Rate Changes

LESSON 6: SETTING UP CAMS

The purpose of this lesson is to describe the function of and show the operation of the cams used on the Model D2 and D4 Escomatics. After completing this lesson material, the Operator will be able to locate, identify, and change:

1. Tool Cams 1 and 2

2. Feed Cams 1 and 2

3. Friction Clutch Cam

4. D2 Counter Collet Cam

5. D4 Drill Turret Cams and Counter Collet Cam

6. Stock Straightener, Stock Clamping Jaw, Stock Straightener Slide Cams

7. Stock Straightener Cam Shaft Ratio

LESSON 7: STOCK STRAIGHTENER

The purpose of this lesson is to instruct the Operator on the basic operation and adjustment of the stock straightener system of the Model D2 and D4 Escomatics. After performing this lesson material, the Operator will be able to:

1. Select, Install, and Adjust Stock Straightener Jaws

2. Select and Install Stock Support Bushing

LESSON 8: STOCK STRAIGHTENER AND STOCK CLAMPING JAWS

The purpose of this lesson is to instruct the Operator on the basic operation and adjustment of the stock straightener system of the Model D2 and D4 Escomatics. After completing this lesson material, the Operator will be able to:

1. Select, Install, and Adjust Stock Straightener Jaws

2. Adjust Straightener Slide Travel

3. Adjust Stock Clamping Jaws

LESSON 9: FEED SYSTEM AND STOCK GUIDE BUSHING

The purpose of this lesson is to describe the basic operation of the stock feed system and its components. After completing this lesson material, the Operator will be able to locate, identify, and explain:

1. Operation of the Feed System

2. Stock Feed Friction Clutch and Hydraulic Unit

3. Types of Feed Rolls, Changing Feed Rolls

4. Installing 2:1 Ratio, 1:1 Ratio Stock Feed Attachments

5. Selecting and Installing Stock Guide Bushing

LESSON 10: ROTATING TOOL HEAD

The purpose of this lesson is to instruct the Operator on the operation of and the basic tool adjustment locations of the rotating tool head. After completing this lesson material, the Operator will be able to locate, identify, and explain the operation of:

1. Tool Head Components

2. Tool Head Adjustments, Axial, Radial, Centering

3. Description of Basic Tools Used

LESSON 11: BASIC TOOL ADJUSTMENTS AND SHARPENING

The purpose of this lesson is to instruct the Operator on the basic adjustments performed on the rotating tool head. After completing this lesson material, the Operator will be able to:

1. Mount Tool 1 and 2

2. Center Both Tools

3. Set Safe Distance From Stock

4. Set Location of Tools From Stock Guide Bushing

This lesson will also show tool removal and sharpening. The tool will be installed and readjusted.

LESSON 12: COUNTER COLLET ASSEMBLY MODEL D2

The purpose of this lesson is to instruct the Operator on the operation and setup of the Model D2 counter collet assembly. After completing this lesson material, the Operator will be able to locate, identify, and explain the operation and setup of the counter collet.

1. Basic Operation

2. Types and Sizes of Collets

3. Installing Collet, Collet Holder, and Collet Sleeve

4. Adjusting Collet Centering, Position, and Pressure

LESSON 13: PRODUCING THE FIRST PART AT SETUP

The purpose of this lesson is to give the Operator a basic sequence and procedure to guide him during setup. After completing this lesson material, the Operator will be able to:

1. Read Layout Sheets

2. Sequence for Changing and Installing Equipment

3. Set Cam Timing

4. Check Collet Timing

5. Final Axial and Radial Tool Adjustments

LESSON 14: MODEL D4 DRILL TURRET

The purpose of this lesson is to instruct the Operator on the basic operation and setup of the Model D4 drill turret. After completing this lesson material, the Operator will be able to locate, identify, and explain the operation of the drill turret.

1. Basic Operation

2. Selecting and Installing Drills and Collets

3. Centering Drills and Collets

4. Selecting Index Trip Dogs

5. Adjusting Index Timing, Drill Depth, Collet Position, and Pressure

6. Adjusting Collet Open Close Trip Dogs

LESSON 15: CONTROLLING THE QUALITY OF PARTS

The purpose of this lesson is to instruct the Operator on using the layout sheet and part print to adjust for:

1. Overall Part Length

2. Shank Length

3. Incorrect Chamfer

4. Axial and Radial Adjustments

5. Cutoff Teats

6. Short Feed