Gear Works, Inc.

No. 4GS Ultra Shaper

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Accuracy and reliability enhancements including, electronic cutter positioning and programmable, variable speed drive.

Rebuild Details 

Inclusive of, but not limited to:

  • Complete disassembly of machine.
  • Hot tank castings to remove all paint and filler.
  • Prime and paint with Sherwin Williams Polane polyurethane machine tool paint of customer’s color choice.
  • Scrape for flatness, bed and base mating surfaces.
  • Scrape for alignment, bed ways, saddle and gib.
  • Grind apron plate thrust surface to restore finish.
  • Scrape for alignment, base to apron thrust surface.
  • Scrape for alignment, 4 point contact.
  • Scrape and refit guide assembly.
  • Scrape for contact, apron thrust washer.
  • Scrape for contact, bronze relieving angle block.
  • Grind fixed, steel angle block to restore finish.
  • Grind cutter spindle O.D. to insure cylindricity and concentriciy.
  • Replace, line bore and hone, cutter spindle bushing for match fit.
  • Hard chrome and grind relieving arm pivot pin.
  • Hard chrome and grind apron clevis pin.
  • Replace and hone for match fit, relieving arm bushing.
  • Replace and hone for match fit, apron clevis bushing.
  • Replace all ball, roller, and thrust bearings.
  • Anti friction coat upper and lower worms and rack screw.
  • Replace and fit thrust plates for spindle operating pinion.
  • Replace and fit thrust plates for rock shaft pinion.
  • Replace upper worm slip shaft with new, hardened steel shaft.
  • Replace crankshaft drive and driven gears.
  • Rebuild or replace pneumatic operating cylinder.
  • Rebuild or replace Par-Check fluid damper, Controls infeed cam follower.
  • Replace saddle traverse fluid damper assembly with standard Parker components.
  • Replace pneumatic solenoid with Parker B461BB553-A
  • Replace FRL with Parker 14G11B18F0GB, including gauge.
  • Replace pneumatic pressure switch with Parker P01909.
  • Replace lube pressure switch with Nason NS-2A-8J/HR.
  • Replace lube pressure gauge with 0-15 PSI gauge.
  • Solenoid and pressure switches use DIN plug in connections for easy service.
  • Rebuild or replace Bijur lube pump.
  • Replace Bijur oil filter with replaceable element filter assembly.
  • Replace and reconfigure lube system for improved distribution. All Bijur components.
  • Replace grease fittings and lines.
  • Install A.B. 800T series push buttons and switches.
  • Install A.B. 855EC status light stack on panel.
  • Install A.B. 194R fused disconnect.
  • Install A.B. 1497 IEC control circuit transformer, w/ primary and secondary fusing.
  • Install A.B. 100C IEC motor contactor and overload for coolant pump.
  • Install A.B. PowerFlex 40 variable speed drive, programmed for internal cycle cutter positioning.
  • Install A.B. MicroLogix 1200 programmable controller.
  • Install A.B. Panelview 300 operator interface. Displays machine status, fault descriptions, stroking speed and cycle counter.
  • Install A.B. DIN rail terminal strip for easy expansion.
  • Install high efficiency, 3 HP, inverter duty, main drive motor.
  • New drive belt and timing pulley.
  • Rebuild or replace, Gusher 11022-S, 1/4 HP coolant pump.
  • Set upper and lower worm thrust bearing preload.
  • Set upper and lower worm wheel backlash.
  • Set upper worm wheel thrust.
  • Set work spindle thrust.
  • Set 4 point contact.
  • Set infeed and rapid traverse adjustments.

                    

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