OPERATING MANUAL

'",':

MR-334

Table of contents
1 Safety
1.1 Safety wamings (waming notes) 1.1.1 Classlfication of hazards 1.1.2 Other pietograms

1.2
1.3 1.4

Proper use
Possible dangers causec by the machine Oualification af personnel 1.4.1 Target grou;p 1.4.2 Authorised persormel 1.4.3 Oblipations of the operator
1.4.4 ObHgations of me user

1.4.5 Additiona! quaiificatlon requirements

1.5
1.5

USے

positions

Safety devices 1.6~1 EJ\lJERGEl~CYSTOP button

1.6.2 Proíective cover
1.6.3 Lathe chuck key 1.6.4 Prnhibitíon, 1.7 1.8 1.9 Safety check Individual protection
geer warnlng and rnandatory labels

Safety durinpoperatlon

1.10 Safety during malntenance

1.10.1

Dísconnectinç

me leme and rnalntenance

maJdng it

safe

1.1 D2LJsing

lifting equbment

'l.10.3Mecnanicai

wotk

1.11 Aocíoent report 1.12 E!ectrica] system

2

Technical data
Power connection

Í'ifíachine data

Dimensions
VVork area
Envíronrnental conditions

Operafinp material

2.1

Emissions

Page2

3

Assembly
'J 1 v. i

Extent af suppíy Transport Síoraqe Installation and assernbly 3.4.1 Requirements of the ínstaílation site 3.4.2 Load suspension poínt 3.4.3 Instalíation 3.4.4 lnstalíatíon drawing

3.2 3.3 3.4

3.5

Fírst use 3.5.1 Cleaninç ano greasing 3.5.2 Visual ínspectlon 3.5,? Run test 3.5..4 Power connectíon 3.5.5 Functional test

3.6

Optiona! machíne accessoriss 3.6.1 Mounting lnstruction chuck flange 3.6.2 Maunting instructíon of collet chuck holder

4

Design and function
4.1 4.2 Construction features Lathe bed Headstock Feed gear Apron Tailstock

4.3
4.4

4,5
4. 6

5

Operation
5.1 5.2 5.3 5.4 Safety Contrai and indicatfng elements 5.2.1 Control elemants Toalholder 5.4. 1 Tool height 5.4.2 Tool angle Lathe chuck 5.5.1 Head spindle seat Adjusting the speed 5.6.1 Protectíve cover of the headstock 5.6.2 Changing the speed range 5.6.3 Speed table

5.5 5.6

Page 3

5]

Adjusting the feed
5.7.1 5.7.2 5.7.3 Selector switch Chang1ng the chan:ge gears Engaging lever the latha saddle ot the tailstock

5.8

Lathe sadots with cross and top s!ide 5.8.1 5.8.2 5.8.3 Immobilising Turning tapers with the top síide Cross-adjustment

5.9 5.10 5.11

Tailstock sleeve Clamping a workpiece into the lathe cnuck
.>

5.10.1 Heplacing tlle clamping jaws on the lalhe chuck General working notes
5.11.1 Fittíng a follow rest

5,1 í .2Coolaní

6

Maintenance
6.1 Safety

6.1.1
6.2

Preparaíion

6.1.2 Restarting
InSPection

and

maintenance

6.3
6.4 6.5

Repaír
Exploded Exploded Exploded 6.6.1 view of top sHde view of cross siíde víew of appron

6.4_1 Spare parts list of top slid6 6.5.1 Spars paris 11stof cross slíde 6.6 6.7
6.8 Spare parts iist of appron view of lathe bed vísw of feed gear Spare parts list of lathe bed Spare parts list of feed gear Spare parts fist of headstock

Exploded

6.7.1 6.8.1,
6,9
6,10 6.9.1

Exploded

Exp10ded view of headstack Exploded view of chanqs geaf

6.10,1 Spare parts list of change gear 6, í 1 Wiring diagram (230V) 6.12 Wiring diagram (400 V)

P.age "-

7

Anomalies.
7.1 Anornaües in the lathe

8

Appendix
8. 1
8.2 8. 3

Copyright.
Termínology/Glossary Product follow-up

Page ~

1

Safety
Glossary of symbols
Il'~.

gives additional indications calls on you to act Enumerations

-7

-,
This part of the operatlnq manual • • • • explains the meaning and use of the warning references contained in the operating manual, explains how to use the lathe properly, highlights the dangers that might arise for you or others íf these instructíons are not obeyed, tells you how to avoid dangers.

In addition to this operatinç manual please observe • • • applicable laws and reçulations, legal regulations for accident prevention, the prohibition, waming and mandatory slgns as well as the warning notes on the lathe.

European standards rnust be observed during installation, operation, rnaintenance and repair of the lathe. If European standards are not applied In the national legislation of the country of destinatlon, the specific applíeable regulatíons of each country must be observed. Where necessary, the required measures must be taken to cornply with the specific regulation of each country before the tathe is ftrst used, ALWAY$ KEEP THIS DOCUMENT CLOSE TO THE LATHE FOR FUTURE REFERENCE.

Page6

1.1
1.1.1

Safetywarnings (warning notes)
Classificationof hazards
We classify the safety warníngs into various levels. The table below gives an overview of the classification of symbols (pictograms) and warnings for the speciãc danger and íts (possíble) consequences .. Pictogram Alarm expression DANGER! WARNINGl CAUTIQN!
1------1---------41..
!j.

Definition/Consequences Immlnent danger that will cause serious injury or death to .' personnel. Risk: A danger that might cause seríous injury ar death to

personnel.

I Danger or unsafe procedure
. .. .
m m •.••••••••• m •• m

that might cause injury to
••..•...• m ••••••••••••••••••••••••••••••••••• •••

i personnel ar damage to property.
1

----1

1 Situation that could cause damage to the machine and

-.···.···.·1 •U-\

product and other types of damage. No risk of injury to personnel.

ATTENTIONl

I Appllcafion
1

tips and other important or useful informatíon

and notes. No dangerous or harmful consequences for personnel or objects.

INFORMATION

In the case of speclfíc dangers. we replace the pictogram

'·' A
,-

/.:,;1.:.. ~•.........
••••• ', -----<

or

General danger

with a warning of

injuries to hands,

hazardous electrical volt-

rotating parts.

age,

Paga 7

1.1.2

Other pictograms

Â
....
_. -

""':C·,

; "y/j;~" ... .. ...;~1(;.,
..... _----..

Warning matic

of auto-

Activation

forbid-

Pul11he maíns plug!

Use protective goggles!

Use ear protection!

start-upl

denl

I·'
·······"···.·····.·

.
.
~.'

. '.
'.

..
.

.
.

.

.
o···

"

.

Use protectíve
gloves!

Use protecnve bootsl

Weár a safety suif

Protect tha environment!

Contact address

1.2

Proper use

&.; ;~;~~:::r~::~~~I.

• may affect proper operation of the rnachlne.

will endanger the maehine and other material propertyof the operator,

The machine is designed and manufactured to be used in envíronments where there ís no potential danger of explosion. The lathe is designed and manufactured for straight tuming and fadog round or regularly formed three-, slx- or twelve-square workpleces in cold metal. castings and plastics or similar materiais that do not constitute a health hazard or do not create dust, such as wood, Teflon®. etc, The lathe must only be installed and operated ín a dry and well-ventilated place. The workpieces may only bedamped ín the lathe.chuck using the spedal cheek-key provided.

If the lathe ís used ín eny way other than as described above, rnodífied without the authorisatíon of company ar operated with different process data, then it is being used improperíy
We do not take liabillty for damage caused by improper use. We would like to stress that any rnodiãcations to the construction, or technical or technologícal mcdlfications that nave not been authorised by company will also render the guarantee null and void.

It ís also part of proper use that
• • •
IH'f'

the maximum values for the lathe are complied wíth, the operatinq manual Is observed, inspection and maintenance instructions are observed. Technical data'

In order to achieve eutting performance, it is essential to choose lhe tight tuming tool, feed, tool pressure, Gutting speedand coolant.
WARN!NG!

Very serlous injury due to ímpreper use.
It ís forbidden to make any modlflcatíons or aíteratíons to lhe operating values of the machine. These could endanger personneí and cause damage to the machine.
Page8

1.3

Possible dangers caused by the machine
The tathe has underçone a safety inspecticn (anatysls ot danger with assessment ot rlsks). It has been designed and built on the basís of thís aneíysls using the latest technological

aovsnces.
Nonetheless, there remains a residual risk. since the machine operates with • high revolunons,

• rotating parts, • eíectrtcal voltage and currents.
We have used construcãon resources and safety techníques to minlmise the health rlsk to personnel resulting from these hazards, If the Iathe ís usedand maintained by personnel who are not duly quaíified, there may be a risk resultinq from incorrect operation or unsuitable rnalntenance. INFORMATION Ali personnel involved inassembly, commissioning, operation and maintenance must • • be duly qualified, follow this operatinq manual.

Disconnect the machíne whenever cleaning or maíntenance work ís being carried out.

WARNIN:G!
THE LATHE MAY ONLY SE USED WITH THE SAFETY DEVICES ACTIVATED.

Discol'lnect the Iathe whenever Vou deteet a faHure ín the safety devtces or when théy are
notflttedl

Ali additional installa,tions carríedout by tne operator must incorporate the préscríbed
safety devlcos. As the machine operator, this wHl be your re sponsibilityl ~ "Safety devices" on paga 11

1.4
1.4.1

'Qualification of personnst
Targetgroup This manual is eddreesed to • opsrators,
• • users, maintenance stuff.

The warning notes therefore reter to both operation and rnaíntenance of the rnachine. Determine c1early and unequivocally who wíll be responsible for the different activities on the machine (use, maintenance and repair).

Vague or uncíear assiqnment ot responslbilltles consfitutes a saíety hazardl Always disconnect the machine plug frorn the mains. This will prevent it being used by unauthorísed personnel.

INFORMATION Ali personnet involved in assembly, cornmissioninq, operation and maintenance must
Page9

• •

be duly qualified, follow this operating manual,

In the event of improper use • • there may be a risk to personnel, there rnay be a risk to the machine and other material property,

• correct functioníng of the lathe may be affected. 1.4.2 Authorised personneJ
WARNING! Inborrect use and mainttmanceof objectsand the ênvironment Only authorised personnal the machine constitutes a danger for personnsl,

may operate the machinel

The only personnel authorised to Use this machíne and perform maintenance on itare tralned and instructed technical staff working for the operator and manufacturer.

1.4.3

Obligations of the operator
The operator must ínstruct staff at least once a year on

• aI! safety etanderds that apply to the machine,
• • operatíon, accredited technical guidelines.

The operator rnust also:':' • • • • check staff's understanding, document trainingJinstruction, require staff toconfirm participatíon in training/instruction by means af a signature, check whether the staff are aware of safety and of dangers in the workplace and whether they observe the operating manual.

1.4.4

ObJigationscf the user
The user must


have read and l.mdefstood the operatinq manual,
be familiar with ali safety devicss and regulations,

be able to manipulare the machíne.

1,4,5

Additional qualification requfrements
For work on etectrícaí components or equipment there are additional requirements: • This work must only be carried out by a qualified electricían or person workíng under lhe ínstructlons and supervision of a qualified electrlclan.

be taken, in the arder given.
~ Dísconnect ali potes

Before carrying out work on electric components or operating units the fOllowíng rneasures must

-7 Ensure that the machine cannot be lurned on again ..,. Check that there ís no voltage

1.5

User positions
The usar must sfand in front ofthe machine.

1.6

Safety devices
Use the lathe on/y with properly functioning safety devices. Stop the lathe immediately if there ls a failure ln the safely devíce or reason. It is your responsibility! If a safety device has been acnvated or has falled, the lathe must oniy be used when • • the cause of the failure nas been removed, it nas been verftied that there ls no resulting danger for personnel or objects.
jf

lt is not functioning for any

WARNING! If you bypass, removeor override asafety device in anyother way, you afê endangering yourself and other personnel worklng wíth the machine. The possible conaequencas are • damtlge as a result of components or parts of components flyíng offat high speed, • contact with rotating parts, • fatal e-lectrocution. The falhe includes the following safety devices: • • • Self-latchinq, Iockable EMERGENCY STOP button Screwed-down protective cover on the headstock Speclal key for the falhe chuck

1.6.1

EMERGENCYSTOPbutton

EMERGENCY STOP

button

1.6.2

Protsctívs cover
The neaostock of the lathe is fitted wíth a screwed-down protective cover.
Prolecti'le COVHf

WARNIN~G!
."
.. "~ ::..:••. .."-.; ..

~

.

'.'.'.
:·0'

Remove tha protectivecover only aftar the maios plug of the lathehas been pulled.

Protectivs

cover

of lhe íaíne

Pâge 11

Top-Tech
Machine & Toots
1.6.3 Lathe chuck key The lathe ls equipped with a speclal key for chucks. Once lhe lathe chuck key has been released, it is pushed out of the lathe chuck by a spring.
CAUTIONl

Only operate the lathe using this key.

talhe chuck key

1.6.4

Prohibition, warning and mandatory labels
INFORMATION
Allwarning labeJs must be lepible. Check them regularly.

~

1.7

Safety check
Check the lathe at least once per shift. Inform tne person responsible age, defect ar change in operating function. Check ali safety devices immediately of any dam-


• •

at the beginning of each shift (with the machine stopped)
once a week (with the machine after every maintenance in operation) and repair operation and information labels and the markings on the lathe

Check that prohibition, • • can be identified are complete

warning

(if not, clean thern)

INFORMATION
Use the following table for organising the checks.

F'age 12

I

t

General eheck Check
Fítted, fírrnly bolted and not damaged

I Equiprnent
I

OK

I I
I I

Protective cover, chaw juck cover

Labels, rnarkínqs Date:

Installedand legible Checked by (signature):
I

I Run test
..... -._ .......

t

Equiprnent

;

Check

OK

EMERGENCY STOP
button

When the EMERGENCY STOP button is activated, the lathe
should be swltched off. Once the chuck key has beenreleased, cally pressed out of the lathe chuck.

-Lathe chuck key

it should be autornati-

I Date:
1.8
For

Checked by (signature):
.......

-

Individualprotectiongear
certain
work

individual orotectíon

geaJ

is required.

Protect your face and eyes: During all work, and specifically work during which your face and eyes are exposed to hazards, a safety helmet with a face guard should be worn.

Use protectíve gloves when Iifting ar handling pieces with sharp edges.

Wear safety shoes when fiUing. dismantling ar transportlnq heavy components.

Use ear protection Beforestartíng workplace. CAUTION!

if the noise levei (irnmlssion) in the workplace individual

exceeds

80 dB(A).
gear is avaüable in the

work, make sure that the prescribed

protection

Dírty ar ccntamínated

hody proteetíon gear can cause dtssase.

ctean lt after every use and onee a week.

Page 13

1.9

Safety during operatíon
wors.
10 the descripüon of work with andon the machlne we highHght the dangers specific to that

WARNING!

Befoi'e aetivating the latne, doubJe eheck that this will not endàhger other peepla and cause damagé to equípment.
Avoid unsafe working practises: • •. • • • • • • • • • •
o

Make sure your work does not endanger anyone. C!amp the workpisce tightly before activating the lathe. For clamping workpíeces, onily use the special chuck key supplied. Mind .the maxímurn chuck opening. Use protectíve g0991es, Do not remove turning chíps by hand. To remove turnínq chips, use a chip hook and/or handbrush. Clamp lhe turning tool at the correct height and with the least possible overhang. Turn off the lathe before rneasurínq the workpiece. The instrucãons ano repatr,
itl

this manual rnust be observed during assembíy, handllng, rnaíntenance reduced,Jor example, becauseyou are tak-

ing medication. '

Do no! work on thelathe·ffyour.:concentrationis .

Observe the rules for preventínç accidents issued by your assooíatlcn for the preventíon of occupatíonal accidents and safety ln the workplace or other inspection authorítíes, Inform the ínsoector of any danger or faílure. Stay at lhe lathe until ali rotating parts have come to a halt. Use prescribed sary, a haimet. protecuon gear, Make sure to wear a well-fitting work suit and, where neces-

Pagi314

1.10

Safety during matntenancs
Inform operating staff in good time of any repaír and maintenance work. Report ali satety-relevant changes or performance details of the lathe. Document ali changes,

have lhe operatíng manual changed accordingly and train the machine operators.

1.10.1

Disconnecting

the lathe and making lt safe

Pull the mains plug before beginning any maintenance or repair work, Ali machine components and hazardous voltages and movements must have been dísconnected. Place a warning sign on the machine.

WARNING! Before reconnecting the machíne, make sure that lhe change~over swltch on the lathe is in the "O" posttlon,

Change-over

switCh

ON / OFF svlit.ch

1.10.2

Using lifting equipment

WARNING!
Useof unstable lifting and suepension gear that might break under load can cause very

serious injurIes oreven death. Check toat the Iiftingand load suspension gear is ofsufficient load capaeity and In perfect condltion. Obsel'Ve the rules for preventing accidents issued by your association for the prevention of eccupatlonal accídents and safety in the workplace ar other inspectíon authorltles. Hold the loads properly,

Nevar walk under suspendeu

loadsl work

1.10.3

Mechanicaf malntenanca

Remove ali protection and safety devíces before beginning maintenance work and re-install them once the work has been completed. These include: • Covers


Safety indtcetlons and warning signs Earth (ground) connecnon
protectlon or safety devlces, refit them immediately after compíetínq the work.

Ir you remove

Check that they are wo(king properlyl

PagelS

1.11

Accident report
Inform your superiora and Optlmum Maschinen GmbH irnmediatety in the event of accldents , posslbte sources of dançer and any actions which almost led to an accident (near misses). These near misses can have many possible causes. The sooner they are notified, lhe faster the causes can be eliminated.

INFORMAJION
ln the description of execution to that work. of work with and on the machine we highlight the dangers specifíe ~

1.12

Electricalsystem
Have the machine andlor me electric equipment checked regularly, and aí least every six rnonths. Elirrtinate immediately ali defects such as loose connections, defective wlres etc. A second person rnust be present during wark on live componente, to disconnect lhe power in the event af an emergency. Dísconnect the fathe immediately if there are any anomalies in the power supply!

page 16

----_._

.... _-----_

..

--~-----------------------------

Top-Tech
Machine & Tools

2

Technical data
The following informatíon gives the dimensíons ano weight and is the rnanufacturer's authorised machine data.

Power connection
Total connectíon rate
Oegr-e8 of protection

TURNER280VAR.IO 230V/1100W/60Hz

r-M~·~hi~-;d;~··-··-·--~ -------. ...

-'=r
1-'

IP54

----j

~_···_·_····_··--M;ei::~g::::t:~:ml -....... f·..·-·..·_-..· -···.··..· ·.·· ····"..·· ·_·.._- -·..--- - -.-- - -.-. ..·-·..
Distance between

-----~-:-:-----i!
. - - --_..................
750 50·2500

..... ======1

.. ;

centres

[rnrn]

~---'------------I
MK4

I

SpíndJe speed [rpm)
~""_N_' " ••••••• _." • ._ •••__ •••••••••••• •••••"._."" " ••_ •••" ••" ••,,,,,._."",, ••,. __ • ••.•••••••• __ ••••

Spíndle taper t ~----_ ... _--------_. ~

Spindle hole [mm}

~

26

"__
t

~:_~_~id~~..! .__ m~
Trave! ot top slide [rnrn]

135
I
75

r····..· - ··..···_·T~·;~~; .. ~f"~~~~~~li .. .. d~[-;;J··-'-""-"--"'-r-"

..··-·--=_..-·..·"155--~·--" --\ ..· ·· ·..
MK2

I I

I

!···-· ..·-T~j,~~;~k··~;~~~;t;~-~~,·[;;:;;l··--······l· · ..···--·······--65·-·-·-----1
~- .. ---- ..-- .. --- - .•... _.---_ .. --.-.-_._---------

Taiistock

taper

I

1

I

Longitudinal

feed [mmlr6v]

~

I
.. .._---

.-.--_.

---~·---

..1

0.07 --0.1 --0.2 0.2 --3.5

;

t··..- ·-..-·--··~
t O ;

pi·í~h-:í~i~~h~--;.. ~·-.. ·

Pitch --Metric

~_.~~----~_._._------------------_._-------_.._-_._-------_. __ . .__ ....

-__-_·_·_·-r-------~--~ __
._-_. -...
--..

56 --.-.~-.---

_.~ _--_. __ .._._-...

i~·~-~;i:~~·~-···· _..-._-__
...
.. ~~-~----.-. -~...
......•............•.. -..

1'..
I

·····-····-··_·
480

..--·--··1 I

! --.-..~.-.-._.---~Ig~~-~~
I,_...........
-

----t-.. -.-.~.--.--. --·--1 -....
I ._--_ .•._---_._ 10°1 ....•._-----, 1, _----_
.

Length [rnrn]

;- --To~~;.;~:91---t--~----j
í

- _ ..•........•...................

_

--

-- ...•......•. _..........

! Work area
L...
Height{mm) i-----~_._._--~--.__
o o

r

2,000 2,200 1,900

Lenglh [mrn]

L

_

Oepth (mm]

Page 17

Envircnrnental conditions
Ternperators j---------

5 - 35 "C:

Hurnidily

----_.--------------------------._------_._--

---------,
Di!
1;

Operatíng

material
Mobiigsar 627 or equivalem

Feed ge8, 1--······--------·---·---·---·---·-----·------------~ 8righl sleel parts 2nd lubricating rdpp!E:s

!

-------·------------~·--------------------~I
Change ge~ís
Ô-._ .•... . ... .. ... '__

Chain oil (sprey bCA)
..

_--,._--------_

...

_-_ _--------,
...

I

2.1

Emissions
The levei cf flDise ernitted by the lathe is less than 70 dB(.;).

INFOR.MATION lf the lathe ís installed ir; an arsa whsre various rnachines are in operation, the acoustic influo ': on the ooerator of the lathe rnav exceed the lecallv oerrnitted neak value in th5
, J ! . ; ...., •• , •

ence (imrnission workptace. V~íerecornmend

tne use of souncprooünç

anc ear protection.

INFORMATION The latne comes pre-essembted.

3.1

Extent of supply
When lhe machine ls delívered, check immediately that the lathe has not been damaged during shippíng and that ali components are íncluded. Also check that no fastening screws have come toose. Compare the parts supplied with the lnformation on the packaging list.

3.2

Transport
WARNING! Ma~hioe parts fallíog off forklift trucks or other transport vehícles could cause very serior evan fatal injuries. Follow lhe instructlons andInformatlon on the transpertcase: • Centres of gravity • Suspension pcints • Weights • Means of transport to be used • Prescribed shipping posltlon
OUS

WARNING! Use of unstable lifting and íead-suspensíon very serious injuries or even death. gear that might break under load can cause

Check that the Hfting and load suspension gear has sufficient load capacity and that it is in perfect condition. Observe lhe rules for preventingaccidents. Hold the loads properly. Never walk under suspended loads!

3.3

Storage
ATTENTION! Improper storage may cause lmportant parts to be damaqed or destroyed. environmental condítlons.

Store packed or unpacksd parts only under theíntended

-'

:::

pag& 19

3.4
3.4.1

InstaUationand assembly
Requirements of the installation síte
Organise the work area around the lathe ín accordance with local safety regulations. Operatíon, rnaíntensnce INFORMATION The rnains plug of lhe lathe must befreely accesslbte. and repalr ln the work area must not be hindered.

Load suspension point

-+ -+ -+
3.4.3

Fasten the load suspension

gear around the lathe bed.
50

Make sure that you distribute the loads evenly

that the lathe cannot tum over while ljfting.

Make sure that no add-on pieces or vamíshed parts are damaged due to the load suspen-

sion, InstaUatíon
WARNING! Danger ofcrushing and ~

overtuming:·The tathe must be installed by at least 2 peopte,
of the base of the lathe with a spírit level, has sufficient fíoor-load capacity and rigidity.

Check lhe horizontal orientation Check that the foundation

-+

ATTENTION!

leads to the superposítion of vibrations between the machlne and the feundation (natural frequency of components). Insufficient rigidityof the entire lathe .assembtyalsorapídjy causes the lathe to reach critical speeds, with unpleasant vlbrations, leading -to bad turnlng-results.

Insuffictent rigidity of the foundation

-+

Positíon the lathe on the intended foundation.

~ Secure the lathe to the foundation or substructure of the machine using the (4) through holes.
O tf necessary, use anü-vlbraton elements (model S1) for your rnacnine substrueture.

INFORMATION The lnstallation site must be designed in accordance with ergonomic workplace requirements. The installatlon drawings described below may differ from the real dimensions (cast parts). The tolerances are in the rangeofthe general tolerances according to DIN 7168 g.

Pag~2.0

3.5

First use
WARNING! Personnel and equipment may be endangered if lhe lathe ís first used by inexpsrt psrsonnel. We do not take Ii'ability for damage caussd by incorrect commissioning.

3.5.1

Cleaning and greasing

-+ Remove -+

the anticorrosíve agent applied to lhe rnachine for transport and storaqe purposes. We recommend the use of stove distillate.

Do not use any solvents, thinners ar other cleaning agents which could corrade the vamish on lhe rnachine, Follow the specifications and indications of the manufacturer of the cleaning
agent. •

....:) Lubricate ali bright machine parts with non-eorrosive lubricating oil.

-+
3.5.2

Grease the machine using the lubrícatlon chart,
oot·~.

~(l__

•••.. __

,,!..••.

...J __

:_.,,

Io. .•••

t-' -. .•..••.•.•. __

._

JlA

Visual inspection
Check the ai! levei ln lhe inspection glass of the feed gear.
r .. _ ,,_.,. ~.. ,...

3.5.3

Run test
~ Check smooth running of ali spindles. INFORMATION For manufacturing engineering reasons and for reasons of precision of fito there may be occasional slight stiffness in the spindles. This will disappear after a short time ln use. ~ Check the state of the lathe chuck and the tuming jaws.

3.5.4

Powerconnection
Connect the following cables:

-+

Connect the electríc supply cable.

~ Check the fuse protection of your power supply against the technical data for the total connection value of the lathe .


::

ATTEN110N!

Please pay attention that ali three phases {I.. , 1..2,1..3)are connected correcUy. 1
Most angina faUlIre resultfrom incorrect cormection, conductor ( N ) ís beíng connected to a phase, • • • for instance the neutral

This might lsad to the followingre,sults: The engine deas get quickly very bet. The eng,ine neise lncreases,Le. becomeslouder,
The engine has no power.

When the phases are connected

wrongly, the guarantee ls being nuU and void.

3.5.5

ATTENTfON! Lathes with frequency converter must not be operated with a CEE plug. Connect the machlne permanently to a connection box (see EN 50178/ VDe 5.2.11.1)

Functional test
-7 Clamp a workpiece into the lathe chuck of the machine ar close the jaws of the lathe chuck fully betere turning on the machine.

WARNING!
• • Mind the maximum chuckopening. 00 no! stand in front of the lathe chuck when turning on the rnachins for the first time.

Pag<.l22

3.-6.1

Mountlng instruction chuckflange Putting on of jaw thuck onto the chuck f1ange
Olean the flangeand spindle nose, putlhe flange onto the spindel 00Se serews. Measure the ínner hoíe of the jaw chuck and turn this value of lhe chuck flange toa diameter as a H7 fit. Tum once é8Síly aliar the fiat serface of tnechutk ftang6. Put lhe jaw chuck onto the flange.
Conslder;

lhe jaw êhuck must leI itself manuallyand put 00 withtheáid of a rubber-faced hammsr (distribute unifonnly easy strokes over the front penel).
and uoiformly.

ciamp clampíng boltsalternatingly

The screws may perform no compulsion onto the driUing wall sinca the chucl< body bends itself etse er lhe [aws are locked in positiún. Furthermore, radial runouts

canoccur,

Refíoishing 00 ttle jaw chuck ia ioadmiasible!

3.6.2

Mountirig ínstructlon of collet chuck holder
Proceed as follows. ~ Mark out the position of the jaw chuok at the spindle l'lange before dismantllng with an e.q. felt-típped peno Dlsmantle the jaw chuck.

;SfJintlm flall!lo (1Sho,H;!p~r seat)

~

~ cíean ali faces of the spíndte nose and of the conet chuck holder extremely
thoroughly. ~ Dismantíe the thread pins of the jaw chuck and screw in the thread pios into the collet chuck Moldar. Measure the run out of the spindle nose, Mark out lhe greatest positive rash of the dial gauge at the spindle nose with an e.q. felt-tipped peno Attach thecollet chuok holder to the spindle flange, tighten the nuts easlly. Pul! in the nuts stepwise ones and uniformly alternating at least three times in succession (you receive the run out possible for best only this way). Measure the run out of the collet chuck holder at lhe conical surface. Position the coUetchuck holder by turningeach 120 at the spindle fiange to the highest run out precision is achieved andassemble after this the coílet chuck holder on íhe highest eircularityaccu0

~

~

~

~

racy position,
~ Mark out the positíon of the highest clrcularityaccuracy of spindle flange with collet chuck holder.

Moosuri'19 po~ftlon

Page23

4

Design and function
The machíne is a universal íaíhe, It has been designedand manufactured forstraight tuming and facing round or reqularly formed three-, síx- or tweíve-square workpieces in metal, plasfics orsimiíar materiais. lhe hollow work spindle enables you to clamp tonger workpieces with a diameter of up to 25

mm.
Thespeed is requleted by repositíoning a V-belt Or1pulleys.

The existíng teaoscrew enables longitudinal feed ano thread-cuttlnq, It ís also possíble to use the machine for drilling jobs with the help of an (optional) drill chuck clarnped ín the tailstock.

4.1

conetnretícn features
• • • • Spindle-bearing arrsnçement with precision balt bearings Powerlul, maíntenance-tree motor Hardened spíndle nose High concentrícity preclsíon of the work spindle < 0.009 mm

·Oil-bathed rounded gearwheels on feed gear . • $elf-Iatching, lockable EMERGENCY STOP button with undervoltage círcult breaker ·.Left~ and right-'hand motor rçtatiotl;controlledbya swltch • índuction-hardened, precisíon-qround prísmatíc bed made of gray cast íron (HRC 42 ~52) • • • Cross andstraight tuming slide with dovetail slideway and adjusting gibs Leadscrew for thread-cuttin9' or feed for straight tuming with change gear set Adjustable tailstock for taper turníng

4.2

Lathe bed
The íathe bed integrates the headstock and the drivíng unit, for attaching the apron and leadscrew andJoeguiding toe laíhe.saddle.and.tailstock.

4.3

Headstoek
The bseostock houses the reducing gear with spíndle transrníts the tuming process, The toots, The work spindle Ésdriven an electromotor, via pulleys. The replacement of the chanpe gears for oíher feeds is carried out on the headstock.
Heaostock

the feed gear and pulleys. The work torque during the work spíndle also
Change gears_
""'.

receives the wcrkoíeces and clampínç

4.4

Feed gear
The teed, gear is used to select the feeds for straight tuming as well as for íhreadcutting. ln order to achieve certaín thread pltches, it is necessary to replace the change gears. The torque of the work spindle ís transmitted to the feed gear and thus to the lead-

screw.

Feed gear

4.5

Apron
The apron houses the leadscrew nut with an engaging lever for activating the automatic feed as well as the handwheel for manual feed, The straiqht tuming and cross slíde are located on the apron wIth

bed guidance.

Apron

; 4.6

Tallstock
The tailstock ís ueed for centring and drüling, supporting long shafts, tuming between centres as well as turning long, thin tapers.

Tallstock

Pa~25

5
5.1

Operation
Safety
Use the fathe onfy under the following condítíons: • • The lathe ís in proper working order. The lathe is used as prescribed. The operafinq manual ís followed. Ali safety devices are installed and activated.

Ali anomalias shouíd be eliminated lmmedlately, Stop the machine ímmediately in the event of any abnormality ín operation and make sure it cannot be started up accidentally or without a uthorisation. NotIfy the person responsible immedíately of any modification.

5.2
5.2.1

Control and indicating elements
Clarripingltlver for

Emétgency ÍlLltton ON J OFF switch

Ouadrupletoolholder

taüstock sleeve

Protecüve cover of
headstock Tailstock

Changu gElar ano
feed labia

SelactorSVlltch

for

011inspacuon

Selectocswltch

tor-

Handwheel for talhe saddíe

Feed acnvsuon Iever

feeddíreclloo

913SS

speed

Page 26

5.3

Control elements

.~

MM/.Q

Feed speed

-fJIIftn/1

Thread • In inches
n

Leadscrew nut disengaged

-fJIIftmm

Thread ~ Metric

(Feed deactivated)

Leadscrew nut engaged (Feed activated) Feeddirectíon

5.4

Toolholder
Clamp the turning tool into the toolnolder, The toof must be clamped flrrníy and with the least possible overhang in order to absorb well and reliably the cutting force generated during the chíp formation. Adjust the height of the tool, Use the tailstock with lathe centre to adjust the tool to the required height. If necessary, use steel spacer shíms under the tool to get the required height.

5.4.1

Tool height

Toolholder

For the facing process, the cutting edge of the tool must be exactly aligned with the height of the lathe centre to obtain a shoulder~free face. The facing process is a turníng operation in which the turning tool feeds perpendicular to the axis of rotation of the workpiece in order to produce a flat surface. The different methods are transversal facing, transversal slicing and longitudinal facing.

s
Tool a<J)l1srod to c!mire heighl TQQl aclj\Jsted llbove centre height 1001 adjusted below
csntre heighl.

Heíght of the toei

5.4.2

TOOIangle ATTENTION!

IU.,",.,! ~.

The tool must be clamped with its axis perpendicular to the axis of the work-

piece, lf it isclamped

at an angle, the

toe] may be sucked into ths workpiece,

Tool clamped perpendícular to the axis of the workpiece

Tool clamped at an angle with respect to the feed dírection
Graphic: Angle of the toot

pagac

27

5.5

Lathe chuck
The workpíeces the lathe beíore tight enough to rectíy, but not so must be clamped firm!y and securely onto they are machíned. The clamp should be ensure that me workpiece is moved cortight that it is damaged or deformed,

~ Clamp the workpiece into the lathe chuck with the aid of the chuck key provided.

Lathe chuck

WARNING!
00 110t clamp any workpieces that exceed the perrnitted chucking capacity of toe lathe chuck. Theclamping force of the chuek is toolow if lts capacity is exceeded. Also, the jaws míght work loose.

5.5.1

Headsplndle seat
Ths nead splndle seat rs designed ás à short-tapêr'se.aL,pOtthe",;~/\·,:· lnstallatian af a quantum four jaw chuck a chuck flange ls neeessary,
Il~'

.

"Optional rnachíns accessories' on page 25

Head spindle seat

ATTENT10Nl Whendlsassemblíng the maehíne a werkpíece holder might fali Cri the engine bad and míght damag;e the guide rail. Put a wooden board ar another approprtate par! on the engine bed ln ordar to preveni darnages. -7 Unscrew the 3 nuts 00 íhe flange for the lathe chuck to remove the workpiece holder (in this case, lhe three-jaw chuck), -7 Take lhe workpíece holder off.

-7 If necessary, loosen the workpisce holder by hltting lt gently with a píastlc-tpped hammer or a rubber maílet,

5.6

Adjustingthe speed
Adjust the speed

by

changing

the position of the V-be!t on the pulleys.

With the "Vario" equipment variant, the speed can be regulated wHhin the corresponding speed ranges with tne alá of a frequency converter. The speed can then be adjusted using the potentiometer on the control panel of the lathe.

WARNINGt
Unplug the shockproof
Tanslon pu!!ey holde with

plug of the lathe before openínq the protective

cover.

iE;(;-

"-

s~onpul!cy f'ulip.ys 01 rrimary transm íssíon .~

Lathe spindle

Sp,ndle pulley

Synchronous

be.li ... V·béll

EieClromOlor

5.6.1

Protectlve

cover of the headstock

10 arder to chanpe the speed ar feed, you must flrst remove the protective cavar.
""7

Unplug the shockproof

plug frorn íhe

mains.
~ ~ Unscrew Remove the two fastening the protective screws,

cavar.

Protective cover af the headstock

5.6.2

Changing the speed range
~ Loosen the nut on lhe tension pulley holder ano release the tension of the

v-belt,
~ Lift tDa V-beH ínto the correspondlng posítíon,

Tensíon pulley hoíder

Ienslon

pulley

Tension pulley

o

Depending on the speed selected, the v-belt V\~ii have to be lifted directlv onto the motor puliey or onto the pulley 01the prímary transrnission,
r

O Handle the v-belt with care. It must not be damaged or overstretched . ..,. Tlghten the tension

puílsy and fasten the nu! again.

Page29

Top-Tech
Machine & Too/s
o

_,o

The correct tension of the synchronous beít has been reached when you can still bend it approximately 3 mm with your index fínger.

ATTENTION!

Make sure the tension

pulley is in contact with tha outsíde of ths V-belt at ali times!

Make sure the tensíon ef

toe V-belt is correct. Excessive or insufflclent tensíon can cause

damage.

5.6.3

Speed table D 250 x 750 G

A B·

C
123
Speed table D 250 x 750 G

Exarnple

O 250 x 750 G

With the belt running from Pulley A to Pulley C on the Diameter-3 pulley. you will obtaín a speed of 2,000 rpm.

INFORMATION In the v-belt position AC3, the physical limits of the drive are being achieved at 2500 min-1 by mechanical frictional resistance. It is irnpossible to nave an effective controlling variabie of 225% in the V-belt position AC 3. The full range of controlling variables frorn 15% to 225% are only available for the v-belt positíon AC 1.
This setting is inlended to prevent the workpiece of the damping jaws on lhe drill chuck. from getting loose by too high centrifugal force

5.7 5.7.1

Adjusting the feed Sefeclor swltch
Use the selector swUches to select the feed dlrecâon and feed speed.
Selector S'wltch for leed dírectlon

ATTENT10N! Wait until lhe rnachíne has come toa complete halt before making any change to theselector $witches.
Selector swltch for feed $peed fiM thtead pHch

Selector swltcnes

INFORMATION Use the table 011 the lathe ror selectínq the feed speed or the thread pitch. Change the 6hange gears if the required thread pitchcannot be obtained with the mstatled gear set.

5.7.2

Changing the change gears
The change gears for mounted on a quadrant. the feed are

~ Unplug the shockproof plug from the

maíns.
-7 Loosen the loeking serew
011

the quad-

rant.

Sióe view of the change gears

~ Swlng the quadrant to the right. ~ Unscrew the bolt from the leadscrew or the nutsfrom the quadrant bolts in order to remove the change gears trom the front.
Gearwheel
Nut

~ Instal! the gear couples using the feed or change gear table and screw the gearwhee'ls onto the quadram again.

Screw

front view of the change

gears

~ Swlng the quadrant to the 18ftuntíl the gearwheels nave engaged agaln. ~ Readjust gear flank dearanee by inserting a normal sheet of paper as an adjusting or distance ald between the gearwheels.

~ lmrnobülse the quadrant with the locking screw. ~ Attach the protective cover of the headstock and recormect the machíne to the power supply.

Pagé31

------------------------------------------------

------

5.7.3

Engaging lever
O The automatíc longitudinal fee-d and thefeed forthread-cutting are acüvateo and oeacuvated using the engaging lever. The feed is transmitted via the leadscrew nut.

-+

Push the engaging lever downwards. The leadscrew nut is engaged and the automatic longitudinal feedls actlvated.

Engaglng lever

Handwheel

Apron

-+ Move
5.8

the handwheel slightly to lock theengaging lever in place,

Lathe saddle with cross and top slide
The handwheel is used traverse the íathe saddte. to manually

The cross slidecan be advanced and retumed by turning the cross slide handwheel.

Cross sfide handwheel

Cross sllde

The top slide (tool sllde) supports the quadruple tooíholder, Use the top slide handwheel to move the corresponding slide,

Ouadruple toolholder Top slide

Top snoe handwheel

_ Top sllde

5.8.1

Immobilising the lathe saddJe
The cuttíng force produced duringfacing, recessíng -or slicing process may displace the lathe saddle,

-+

Secure the lathe saddle using the tightening screw.

Tigthening screw

Laíne sàddle

Page32

5.8.2

Turning tapers with the top slide
It ís pcssible to turn short tapers with the top slide. -7 Lcosen the two nutson the left and the right of the top süde, -7 Swivef the top slide. -7 Clamp the topslíde again.
Top sllde

Nuts

Taper turníng

5.8.3

Cross .• djustment of the tatlstock a
The cross-adjustment of the tailstock is used for turning long, tnln bodies.
Lockingscrew

--+ Loosen the

locking nut of the taitstock.
Fronl adJuwng screw Locking screw
Scala

-7 Unscrew the locking screw approximately half atum.

Cross-aqustrnent tailstock

of the

O By alternately loosening and tighlening lhe two (front and rear) adjusting screws, the tailstock is moved out oítne central posítlon. The desíred cross-adiusíment can be read off the scals.

--+ --+

Flrst retighten the locking screw and then the two (front and rear) adjusfing screws. Retighten lhe lockíng screw of the tailstock.

ATTENTIONl Check clamping of thsteilstock and the síeeve, respectlvely, for turninq jobs between centresl Fit the securing screw at the endof the falhe bed in order to prevent the tailstock from faUing off the lathe bed,
Securing screw

t.atne beà

Page33

5.9

Tailstock sleeve
The taílstock síeeve is used to hold the tools (bíts, lathe centres, etc.). ~ Clamp the required tool in the tallstock
Clamping íever

sleeve.

o

Use lhe millimetre scale on the sleeve to

readjusl ano/or adjust the tool. ~ Clamp the sleeve with clamping lever.

MiUlmelrescale Handwheel

Tailstoc1\

o

Use lhe handwheel to move lhe sleevs forward and back.

The sleeve of the tallstock can be used to introduce a drill chuck for holding bíts and countersinks.

5.10

Ctampinga workpiece into the lathechuck
When the workpiece is being clamped unprofessionally, there is a risk of injury as the workpiece may f1y off ar lhe jaws may break,' The following examples do not show ali possible sltuations of danger. The workpieces ,aretomecclamped,:safely':andtightlyon the lathe beforestarting lhe operation.. The clamplng force isto be'dfmensioned -in a wayto make sure that the workpiece is securely dríven and that there are no dangers ar deformations on the workpiece. WARNIN'G! Do not elarnp any workpieces thatexceed lhe permítted chucking capaclty of the lathe chuck. The clamping force of lhe chuck is too low if lts capacíty is exceedsd, Also, ths jaws may come tocse. incorrect

correct

Addi!iona1wppd!1 over conter.

Clamping diameler large, .

100

Page 34

Support over center.

snon,

Worlq;ii\l'Ca i~ too heâvy and clamplng grade toe

enlargas cíarn ping 9rMe.
____ Enlargeíl clamping grades are not available for thts Ihre(Ha'N cnuck, PO~S!bly use largar l'i3U1Il,

Glall1ptng diameter too

snort,

Clampon lhe largesl CIBtnpiflíl di"meler possible.

5.10.1

Replacing the clamping jaws on the lathe chuck
The clamping jaws and the three-jaw chuck

are equípped with numbers, lnsert the clamping jaws at the correct position and in the right order ínto the three- jaw chuck. After the replacement, bring the [aws completely together in order to control if they are inserted correctly,

Three-jaw chuck I clàmping jaws

5.11
5.11.1

General working notes
Fitting a follow rest
The lathe ís prepared forflttiog a follow rest,

~ Remove the two protecting screws In
the lathe saddle. ~ Attach the follow rest with the help of thread screws.
Protecling screws

Lalhesaddle

5.11.2

cootant
Friction during the cutting process causes hígh temperaturas at the cutting edge of lhe tool. The tool should therefore be cooled during the cutting processo Cooling lhe tool with a suitable cooling lubricant ensures better working results and a longer edge life of lhe cutting tool.

Pago 35

6

Maintenance
In this chapter you will find important information about • • • lnspection Maíntenance Repair

ofthe lathe, The diaqram beíow shows which of these headings each task falls under.

MAINTENANCE

'U\~

a• •

lIlustr.6-1:

Main!enance· Definition according to DIN 31051

ATTENTIONI Properly-performedr~9utar-maintenance ,is an sssantial prarequisit.eror • safe operatlon • fault-free operation long servic.e fife of the lathe and the quality of the products you manufacture.

Installations and equipment from other manufacturers rnust also be in optimum condltion, ENVIR-QNMENTAL PROTECTION During work on the bft-holder head, make sure that

• •

coflector vessels are used, with sufficientcapacity lected. liquidsand olls are notspilt 00 the ground.

for the amount of liquid to be col-

Clean up any spílt liquid or oils immediately using proper oll-absorption methods and dispose of them ín accordance with current legal requirements on the environment.

Cleaning up spiUages
Do not re-introduce liquids spilt outside the system during repair or as a result ot leakaqe from the reserve tank: colfect them in a col!ecting vessel to be disposed ot

Page36

Oisposal
Never dump oü or other pollutant substances in water inlets, rivers or channels. Used oils must be delivered to a coIleclion centre. Consult your superior jf you do not know where the collectíon centre is.

6.1

Safety
WARNING!
The consequences of lncorrect maíntenance and repalr work may includa: • Very saríous injury to perscnnel workiog 00 lhe lathe • Oamage to the Iaths On!y quaílfied

,

personnel

should carry out maintenance

and repaír workon

the íathe,

6.1.1

Preparation WARNING!
Only carry out work
01'1

thelathe

if it has been unplugged from the maios power suppl:y.

~ 6.1.2

Attaeh a waming label, Restarting
Before restarting ruo asafety check,

WARNIN'G!
Before eonnectlnq the machlne you must cheek that there is no danger for personneland

thelathe is undamaged.

page37

6.2

Inspectionand maintenance
The type ané extent ot wear depends to a large extent on individual usaçe and service conditions, For thls reason, ali the íntervals are only valid for the authorised conditlons,

Inferval
Start of work afterevery

Where?

What?

How?

ma intenan ce and repair
operatlon Startof work after every

Safety check'

~. Lubrícate ali slideways. Lubrlcate ~ Lubrícate the change gears andleadscew lithiurn-based grease. slightly with

mamtenance
and repair

operation Excessive clearance in the top slide can be reduced by readjusting the tapered gib. ~ Loosenthe counternut,

'7 Turn the set screw slightly clockwise and secure the set screws again using the counternut. . INFORMATION A 90° turn of the set serews corresponds to a travel of 0.2 mm. Make any readjustment of the set screws in small steps. as required Readjust
SeI \lCfem wlth counternuts

Taperedgib

Tapered gib at lhe to;) sllde

Page38

Interval

Where?

What?

How? -7 Check the oíl levei ín the gear's inspection glass. lt rnust reach at íeast the centre of the inspection glas$. 07' If nê'cessary, fil! up to the reference mark with Mobilgear 627 or equivalent oíl.

,~~rt9f

wo(k
Visual lnspection tnspecnon glass

. after every

.mslritenànêe
and repalr operaííon

Oil inspeclion glass of the feed

gear -7 Use an adequate coUector vesse\ wíth suffident capacity for íhe oi! change.

~ Unscrew the bolt óf the outlet,
-7 Unscrew the bolt of the charging hole. -7 Clese the outlet when no more oíl ismnning

off.

~ Refill with Mobilgear 627 or ao equivalent oil up to the reference rnark in the centre of the inspection glass using a suitable funnel in lhe filling hole.
Outlet

'~-:ev.e.o/}~r~. -,-

Firstafter 200 hours lnservire,: thena.fter

-Oi! change

Gear openings

P89a39

lnterval

Where?

What?

How1
~ Lubrícate alllubricating nípples with machinery oil.

LubrtcaUng nlpple on leadsCfe'lll

Lubrícating nipple on rallstMk

o
o
tO 1--. X

o
tO

Lubrlcating nlpples on lathe saddle handViheel

everymonth

S
Q)

Lubricate

:E
C\l ...J

Lubricallng nípples on la.the saddte ••ntl CfQ:i;{; slide

Luoricatlng nipple on cI1ange g2ar prlmary transmísslon

Lubricatiog nippíes

Page40

Interval

Where?

What?

How? Excessive clearance in the slideways can be reduced by readjusting tapered gibs. -7 Loosen the counternuts. -7 Turn the set screw slightly clockwise and secure the set screws açaln using the counternnt. INFORMATION the set screw corresponds toa travei 0.2 mm, Make .any readjustment ofthe setscrews in short steps. The tapared gib for guiding the lieadscrew nut has been factory-setand does n01 normally need to be A 90°' turnof

of approxlmately

readíueted,
Set&CH;WS

Tapared gib

as required

Readjust

SeI screws

(}J

cross slide

Se! scrsw of apwo -

Tapered glb

Null> anel setscrews

Safety raJl of the laíhe sacote

INFORMATION The spíndle bearínçs are permanently greased. Greasing duríng the malntensnce mtervals is not necesssry, Further greasing of the spindle bearings is oníy necessary in case of de- and

remounting of tbe spindie bearínç.
Paga~·1

6.3

Repair
For any repaír work. getassistance trem an employee of Optimurn Maschinen GmbH's technícal service

ar send us thelathe.

lf the repairs are carríed out by quallfied technical staff, they rnust follow lhe indications given in this manual. Optimum Maschínen GmbH does not take responsíbility nor does It guarantea against damage and operatínq anomalias resulting from faílure to observe this operatínç manual.

For repaírs, only use •

faultless and suitable tools
original spare parts or parts from serias expressty authorised by Optimum Maschinen GmbH.

6.4

Exploded view of top slide

6.4.1

Spare parts llst of top slide

Name

2

'---<._-------, 301
f'ulloy Clamplng nut q.uacJtup~)le loot holoer Washer

$feel ball

31 32

fie'xllg<lna! sockutl1
SC(éW

AfiachfnMI

handle M5x12

elampiog

M\,It

'Hex,mon<l! socke1 he<l{l
33~ ~scre.~_,_V_I __ __ ~

~-+

+~~_ ~ _~
M5
M5x6

Quadmpple fool holder Hexagpnãi sOLokeTii.eâd semw

SoaR
7 Glbtopslide Chipshíeld 8 37 Hoxagclnal case

Top sliOe
Threáded bOll {llJad.NPple (001hokíar

r-: 38

"

i

t-je~ago~a'SOckotl1~-;;di sceew l'

t-t

M3xB

10
11

stoppin Spriog

!

, 39SCfElW

!

j

.

NUI--r-.........j~'"'--M-.3-,

H~;~gonalsocket head 1_-

12
13 14

FMl'lgpí'n
lhreaded boI! HexagQnal soc1<.etnead

Washer

scn;..yt
Nill

r
,

3
M6x16

I

Chip j)foléCllcn cómpléle~l

3

M6

15

Sj)ll1cJle nu~ top sll{ie Oovela)1 guldew.ay !ar> slRle

17 18

1

Boate col1arWinKeJSI\ala
top slljjé HexegQflll

sock.el head

19 20

scraw
Spmdle iop sllde

21

S!id(~Ilearing

22

Bearlng pedestal sr--indle top slkle

25

Le'lêf haoowheel 1015Sllde LéVêf hàndwhécl top $!kl~

27

Ci,lInping 0011rever tlantl\lh~1
Paga 43

28

6.5

Exploded· vlew of cross slíde ,

6.5,1

Spare ptlrts f1St of erosa sllde . .. r.- .
Name

l~
,o..

i"age 44

6.6

E.xploded view of

appron

93

6.6.1 o e,
1

Sp.are parts llst of aeoron
Name
13011.' clamping.flJver

tiS

a

s, •...

üi

s
Ma

!

I

I

o c,
78

tiS

Name
Hexagonal socket heed scrow DJN 912

a
..__

i5

(j)

~

a
88 89 9{) Spring pín DlN 1481 Collar for Illverfeooing Siroke pullev lock nu! Stroke pívot lock nu! ...... ·f· 92 lÕCK

>. •...

(j)

~

~"'2"--C;;~mpil1g 40

~-_.--.----.~.~---j-~~~-~~
... -I--··.. __·~··_,-··~·l-·_···,·~······! ~·....
~'~-r-"""'-,-.~-_ .._ ... ~
72 H<ll1dWtmúi bed slide

lev~;-

M5x25
4x50

.~•.... t-r-....•._.•.._._-_ -

+r- , -t-.•_ •.•__ ._ ••;

Oi! nlpple Appron

2

6mm

79 Thrust bearing'.._. •... --~,· _ .._······_ .... _ ..-t-..··_·-l··.... •.. ··"_·······i ....

n

._..._ ..__..._.,,_..._M.~_-._-.__ .. .
1'1 ,
74

····_~_··! .. ···~·-i .. ··• · •

1

80

Shaft wlth loO\heó

whee·1 DIN 6885·
A3x3x9

UwerhanÓ'A'heel uM s!lde . ~"- . ~-Clamping boHlever
hanô'wheel .

91

81

Fealher key

·f···

·· · ···!

nut

[ ...•

- ._

Thrí;1ad pio DIN 91(5
8

93 94

Guide rall

171,

IOCk. nu!
Hexagonal h,ead scrsw sockst DlN 912

I

Too!hed wheel cornblnation

HeXilSOl'1 n"t. ",;,11. sacuring DIN 985
flexagonal socket head screw DlN 912 Scale colfar handwMel bedsllde 2

Me
M12x4ü

M6x1G

í---.~-~~,'~,-~,~ •.. ~,,,.-.~.~.·_.,'+-,.,..,.. .... ... I··.. ,. _ _j 76 71 Retillning ,Ing Bearing pedesl!ll
OIN 471· 14x1

95

Hexagonal socket head screw DlN 912 Hexagonnut

MSx40

M5

97 98

s,'1eeJ naU Sprlng

Page 45

6.7

Exploded view of lathe bed

228
229 \

~~

----221

23

Pagi; 46

·~~'-

6.1.1

Spare parts

~I'fst lathe 01

bed
o c..
!li

Name
AUenscrew

6
1

I
I

.':
';:-.

Handwheel

17 18 19

Nu! Se!screw Gradualeá oollar oftailstock

!

i

20
21
22

Handle

!

I
NUl

I

Wa.sl1er
TaUstock Tallslock moent-

23 24

ing piare
Se! screw ($tud
boll) Clamping

2
....... __

._---_.)

i

plalta

·-1-----------·1I
i

I
Nu! 2

4QOV

i

. ;t~:-:;·-·
~:!•• ~

2;lOV

--------~!.--1--.--~ ____ w_~_h_e_r I~~·· __ ... ._ _
2
I

i

Rack

paga 47

6.8

Exploded view of feed gear

c
399

/

I

A

319

/

-,

242

6.8.1
!IÍ Q.

Spare parts íist of feed gear

O

Nama
012

!IÍ Q.

O

Name
Plate
Gearfôfk.

l:>-

lã !

,êi)

;!t.

40 41"

2

3
4 Shaft C O.ring

2

5

18gg12 I
•• ••

1

L--

I

42

Selector swítch marklng

I

2

6
__ o .••• ------~

Geal'iVhee'---r-T
Featharkey

7

1 I

-··,--1 -1
_-.--••

4 x 30

11
12 13 14

......... SeI screw for ouUel Set screw for chargíng.hQle Screw Screw Flange Bearíng (jea.lwtmel

_-------_._._--

Gllar whú!}! box

ZG$/8
ZG3!8
M()x10 M()X10

15 16 17
18

180202

19 20 21 22 23
24

Shaft

1215

-------Geilt\Vtleel

Shatt ring

__-_
..

.......,...

..,---_.
Clrcl1p

Feather

key

Ll:lflg·lace plnl,on

Featherkey
26 Lock wasnsr

27 28 29

----

Gearwheel Bearing

Flange covor of

leadscrew

31 32 33 34 35

37

Pin

38

O-rlng
$haft 2

~"age 49

6.9

Exploded vlew of headstock
401 .--/ .. 402
,i'!.T

403

419

1426 427 . \
'iP-

l.,~_\
..
4~8

429 ,

ft .-' ~.~

~"O

í/.:J \

.·~·wfl:..J

....

437···· ~

~r
439

430<'-. ~.,. 431 ~
432

.. ~

44Ó

page 50

6.9.1

Spare parts list of headstock
til

o c,
I

Name

51!
_-''' -"14:-1 O
..j

:>.1

I

IlIi I
i O

I o. I
!
I 26

.

Narne
Bi,laring ,

__-r--;:_ .._ -._-_._.".-:+ .. .._ 2.

I

I
I

Charaoterísücs pta\é
Fasteolng screws

i 1-----1
18(J101

I

4 2

[3."r" Pf~;~~~:~~~~Of .
.. 51--' ·_--~+_··~j-_·"···_·,-"--"~·-i
4

I
I I

I

Nu!

4

M10

r.. T.. ·.. _..
28..
29

n. I
27

Comolnaton

01 syn·

chronous I:YeIt ul1ey p anil V-belt pulley

·$ .. .... ~;;.-;-·_ ·_-_ ..
Wi'lsher 1

-I-~' ... - --1

" I
I

01<,5,32

(+ 0,12 f-(}) 84 teeth

I

i

~..,...

••,.."",, . .•. ~""="'~_.~.- ."."""""""""'''''''''''''''''' .="""'"'.,. .. '."'-.'''=''''''-.'-.''''''''''=''''''''''''''

!
V-bel! pu!ley cornblna ..
tíon

028..6 (+ D,07 J -O)
18 teeth

Drlven shatt of motor

s

Bear1ng 31

10
11

----~. -~
.. _.

32
M10

Nu!.
wasner

34

i

wasnsr =_.==~--=-j
Al!en screw

... ~ ....Jl=~=-·--

12

lU

~·36!E- ..C-ce-~-I~'-I~-P-~~-'";-~-;-f-lb-.n..

+-,-ll'..~.. ·_·

1

~_._."==-

13 14 15 15

-Screw
Beilring R.ing Bu~h
200710SE

3"/

Shali of tensionpuiley

I

UI
i

..
~earing~_

L~:_.{
I ' I 39 IL__ j

......J_~._. ~~~
•. ~~. __ ~_I

I
Tenston pune)'

I
22

40

i

Clrclip 1

------

I
--_._---,Spring w8she~
24 Driven $haft of motor

I"
Gates 230XL

Pml{Jctlve cover af tleadstock

I

25

svncnronous heI!
i

1
i
'

I !_._~. ~l

x ·i5

paga 51

Pag~ 52

6.10.1
'!!J

Spare parts list ofchanqe ~ ,..., ..."

gear

-_._-.....-----_.~-"_.:---.----~-_ ....,
~
Nams

-

<li N

(j3

503

Change

Qê&í

ra5!

235rnm

i

I
;

504

I

8f:afing ~:relje~t"31 é'h:ang::::: g2af râii

~-_.~---.l--.--.----.-.-.---.j

i--' h~:i~~~:~: ~~~~~1t~--'--;--+--~~:-1~--~
). so.2-t--·-~-~·~~·---·-·------'-T--·'-·-f-·······65-t;;;h'-'1

I'

'.

mCJ[juie 1,.5

:

i,"""'-'·.: ..

·=··;·-······-····-··-----=~,,~!
BD ;"eU""
rnod lj!·2 1: 5 7ô ~üeth,

~---,-,--i..-- __.

.. _ .__ _ .

moch~i~ 1~5

ro teeth.
506
rnçJc:hm:~ t. '5
65 t~!0th. rtj{)rJu!e 1,5-

charqe

gi;~.\: r=Bmrn. Pi=1Am.m

(-/J

!eelh,

ITIDdlJ!e 1.5

L_~_,J.~m~,_
Q.

;

:

50 \eeth.,
_ó,_ul~e~l,:~.~ ...

4G íeeth. module 1,5

~----~._----_ ..._-~
G'lorJ:J!e

30 iBelh. moduI81:.0

25 teeth, ~! ,S

521

2

521

.incking wnshcr

2

Page 5:~

:~1

6.11

.~
:,1"1 .;':...

f~ ·--r:-:~,- ~;o~" c:~~~ Wiríng diaqram

TURNER280220V-240V
n

r

-J- -- - ~-~ 1--s---T----6-·r--7--.::-T~o)

s:-~ [)) O'
r)

:!,
~
.._-----

.1:)
~

.'

iN I!

-----------_ PE'-"======~=================~====~====='---'--'-'--'-'-'-'---~=~~==~======~====.:~==~.~======= (õi Ç(~J

.:
I I

õl ()
r-,L;-),;(~ m
I!I

·-l
_j

O

(fi

::r

. ~

\d

q6

\

d8

01
'I

~

.

1- 9"l
I
o~ o

_J
- -..

o·····iú·······:······-_··--··························............. ..-

r---I=B------;====~~-=~-=~-±. - =-}l_ I
.J ;

-1

-.-.---.-

Chançe-over R/L

switch

I
.

k
,

Z2

Ul

Uc

M)

6;~l J I
1 -._~

l

_.-

-

"-.

---

._-_.

[--···-·--·------i~;·~-i~9d -.-.-.--.---.. ia g~~~ .. --.- . [ 2 20 V.=24_~~

]1di·tj()~~rE~~;;.·-·::.=~

~"

!Vlachine & /ools

H
ir---!
I

i
I~
I
(j-I

I
!

--I

I~T'---------11(....
!

I

I
;----------i\.
1

o

I

I I
i

r.
lU>

rii
!

I I I

1

!
!

;-----'''''"' "

r

I I

!-=-~

i.

I 1
!

I .

I

I

I

I I

f,

''

I

I
í.. O;

I
> o
!lJ

I~
!

Irrd

I

!
!

I
!.rI

! I
1

I

L-j
I

I

j >i

UQ:

!: s:

Ol~

",

I

i
I

I i
i
I

i0-JI
i
r

i !

I I I
I~

;
i,

r
!
~

I

.

!~I
1"")
._,_.

L.LJ
.... __ . . _

.
l_'

~

~--.J-.Jzn

6,11
L ~E _=-__

TURNER280Vario
Fuse

Eleclric schematic diagram

AC110V 160Hz

-----.---FE3==J-----~L-

=_--__ __ .

l- -.-

~_._=__------~-.---~7------------.-Magnetíc cont actor

1,Smm2

1--®-~3--..

®I
@I
1

Change over swítch
1-- -----

I@
1_

G)

r
Contad

®

CDCDCDCD:
1.5mm2

____ J
1.5mm 2 Motor l1Kw

Fíner Transformer Spe~~ Induces head
I

O,75mm2
L N PE PE

G S V PE

c=:J--1_ G _~ V
Potenhometer

O.5mm2 green ellow red

P1 P2 P3

L1

L2 Control board
A+

A-

,

->

()

7
7.1

Anomalies
Anomalies in the lathe
Problern ._--------_._-;_._._----I Cause f possible effects

! Solutlon

~~=~~~J~f~~~:::::c;:~e:~~-~
j Surface of workpiece rough

i
i!

toa

i.

Tool

blunt

Tool sprinçs Feed too hígh

Resharpen tool Clamptool with lessoverhanq Reducefeed

IH-H_' . . ... ! Workpiece is becomíng

I I !

Radius

at the tool

tip

to little (taüstock

lncrease

radius

Cenlres

are not aliqned

Adjusttallstock Align top
i

to lhe centre
well

coned

iI

has offsst) ' Top síide not aligned well (cutting

stíde
feed

with lhe top slide)

~
r-i

Lathe is chatíerinq

.

._______!

I•

~-_·_··-·--·---------·----i
Reduce ._'_H_av_e the main bearing readjUste~-1

Feed too hlgh

(' have clearance

Maio bearíngs

i Centre runs hot

I'

!
!

Workpieee

has

expancec

!'
i

Loosen taüstock tip

-li-O-O-I h-a-s-a-s-h-o-rt-e-d-g-e-I-íf-e-.·.··-tt-· ·_-G-u-tr-!n-g-s-pe-ed~to--O-h-i9-h-~~~-tI-.-····-R-e-du-e-;e-e-u-tt-ín-g-S-p-ee-d-------1!
Crossf.eed lnsufflclent toa high cooling
..•

Lower crossfeed/smooth

frnish

(allowance no! over 0.5 rnrn) More coolant
i· íncrease Correct clearance angle of the

~.~-~~

...•.......•.•..•...... .:,;""",,-~"""""'--r--"~" ~~ _. -_...

_ ...•...•..•••.. _.-"-"'-'---~

Flank wear toa high

I
1 I

!.
1'

Clearance

angle

toa srnall (tool
to centre

"pushes")
Tool tip height Wedgeangle toosmall

n01 adjusted

I

I
I
i

1.

height adjustment

tool
íncrease wedge angle

i

Cutting edge breaks.off

j •

(heat bulld-


[ •

u~

I
I I

Grinóing

crack due to wrong 0001-

Cool unitcrrníy
Have the císarance in the spindle
bearing arrangemenl readjusted

ln9

i

Excessiva clearance in the spindle bearing arrangement (vibratíons)

Cut thread is wrong

Tool is clamped íneorrectly ar has been started grinding the wrong way
Wrong Wrong pítch diameter

Adjust tool to the Gantre- Grind
angle correctíy

AdjUst the right pitch

! .__

.w ••.•.. w ••••

.w •••

•.•

_w.••_ ••_._.w. __.. _, __

.. _.._w._..... _.

~..

W".

•• __ •__ ••

_J. ~~~~'"~~_~~~w~~~_~t,~~~e2~:'" __ ,'"

i

10 a previous

step, turn the work-

8
8. 1

Appendix
Copyright
©2005
This document is copyríght Ali derived ríghts are also reserved, especlally íhose of translatíon, re-printlng, use of figures, broadcast, reproductíon by photo-mecnanícat or similar means and recording tn data processínç systems, whether partia' or total. The cornpany reserves the right to rnake technícaí alteratlons without prior notlce.

8. 2

Terminology/Glossary
Term Headstock Explanation Housing for the feed gear and thesynchronous belt pulleys Split nut whích ençapes ln lhe leadscew Clamping tool for holding the workpiece Device for holding tne bit Slide on the slideway of the machine bed which feeds parallel to the tool axís Slide on the fathe saddle whích moves transversely to the tool axís Swivelling slide tre Tool Workpiece Taílstock Rest Cutting tool, btt, ate. Plece to be turned or machined Movable turníng aid FoHow ar steady support for turning lon9 warkpieces Device ar clamping aid for driving pieces to be tumed between centres
ali

Leadscrsw nut Lathe chuck Drill chuck Lathe saddle

Cross slide

Top slida
Taper rnandrel

the cross slide

Taper of the blt, the dnllchuckor

the cen-

Lathe dog

..:

Pag..; 57

8. 3

Product follow ..up
We are required to perform a follow-up servíce for our products which extenos oeyond shíp-

ment.
We would be grafeful íf you could send us the foHowing information: • Modified settings

• •

Experiences wíth the lathe, whích could be important to other users Recurring failures

No

Objectof testing

Drawing

Permíssib.le

Measured

[mm]
1--:

[mm]
A: t>.c>v~ B:
().~c»

~B ;,

A: 0,009 B: 0,009

Run-out oi I
spindle .and períodical radial slip ot spindle ,

aI--

~A

r'--l
I

I

I--

d
L-

0,009

,

GI--

2

Run-outof spindle nose

0.0"

.r

r~
I

I

.'

f-

Run-oui ot 3
intemal taper of spíndle

G-

II II

9'
A

A: 0,015

A: ".OlJS B:
0.02.

=1-

B:O,03

'-

1
II

I
I

4

Paraflelism of taílstock guide A = in the vertical plane B:= ln the horizontal plane

n +.
~ 50 !E-

A&
._-

I

A: 0,025/50 8: 0,015150

A: 0·(;>2 B:

·S

OC'°S

11

I
I

I

Page 58

r

9 Test Report
No
Objectof testing Drawíng

Permlsstble

Measured

[mm]
),B

[mm] A:
(;>"t:>v~

;:x

A: 0,009 B: 0,009

f-

1

Run-outof spindle and periodicaf radial slip of spindle
'"1

B: o·~c»

G

..

f-,-~A

r'---l
I

I
f--

d
'-

.

0,009

O2
Run-outof spindle nose

fo·oe>
.r

r~
I
..

I r-

I
II

3

Run-out of interna I taper Qf spindle

G-L-)

9"
T
A

A:.O,015

A: B:

o·o,,!
o·o}.

.-+

B:O,03

I
r::l
I

I

AÓ-o
4
Paraflelism Of taílstock guide A = in the vertical plane B = in the horizontal plane

A: 0,025150

A: o·~2 B:

n
+~ 50 k..,

B ---

B: 0,015150

ocoS

11

I

J

I

Page 58

5

Headstock (fvfT3) and iaílstock (MT 2) centres for same heighl abave reference plane

r-Khfl

Ar ()--D
B'

"

A: (J,03

A:

I~i
HY"

,

'=r

rr-1

.-

I
Parallelism oi spindíe exis with carriage I jmovemem ' I A vertical I plane B horizontal plane

~

I

II

I

I
I

().02-1

A

I I
I
A: 0,03/250

~

A: B:

li

I

-~

6

=

fT I)

1
~

O
250 lE-

--=t~

l~E

0'°5
t>,o~

B: 0,031250

I

I

=

1

i

i

I
1

I

I
0,0/"/75

r
I

1
7

Itop sl:de .wIth
j

II Paralie/1sm. ot
spindle and

~1ll - <q w.1,1
I

I

'--i

cetneçe
movement

I

I
(J,V2.

,

&:-,
1

I

I


I ~

+---+

~

I
0,04

8

I ! I
I
I

Run-out chuck

ot yaw

O
-

D
D
U .
n

I
I
ç.{?~

L
--

Run-out ot yaw 9

I
I
I

chuck Objecl ot testing A: 020mm B: 030mm

~rr
1
~I ~

2 ., <)

A) (j 20mm

A)
1: o-c> 2:

,
!
j I

1: 0,04

I

.2:

O,08i100

o. C' 2o,taL
0'('1

Li

1 .,

1
I
e,

B) 2i 30mm 1: 0,04 2: 0,08/100

B)
1: 2:

I

I

I
Inspector:

~

Date: 12
Page 59

a) Damages ot tecquer

o

a) Connection and functíon b) Funetion emergeney bush button

o o

b) Rust damage

o o
o

c) Identificatian plate data correet/y, comp/ete/y

c) Connection points in lhe
engine terminal box attracted

o
o

d) Transporidamages

d) Motor clockwise left hand motíon

rotetion,

a) CE sign
b) 3-yaw chuck

D
Q
Q

O O O O

.a) Drive belt tension

Qt

O
O

.b) Top siide taper gib clearanee
c) Cross s/ide ieper gib clearanee d) Top slide spind/e c/earanee

I

~

n

c) Quadruple toolholder

O
Q t.......:
r

O

d)Change

gear set

O
Qt

O

€) 2 fixed center and toolbox

O

€) Cross siide spind/e c!e~rance

LV

n
L.

f) Acceptance and lnspection

repor;
!fc~'

Q

O
O O

O

Csmage surfaces cleaned

~

n

O

g) Drehfutterschlüssel Ciiuck Spanner

G

g) SpindJes c/eaned and greased, operation smoothness

G
r ~

O

h) Operating menuei

B

.h) Tellstoct; tunction I wedging

O

a) Quiet running

o
O

Additional parts

b) Temperature of both spind/e bearings, whi/e running with - 1DOOmin-1eiier tôminutes within lhe range of.50 -

ooce

Seria! no ot lhe mechine

Customer

Inspector:

Date:

Place

Page 60

Packing List

D280X7(J()G Vario
NO. 1 2 .3 4 5 6 Description Bench Lathe Plastic Sheath Operating Manual Oualification Certificate Packing List Toolbox(including:) 1}Fixed Center 2)Allen Key 3)Handle 4)Oil Gun 5)Reverse Chuck 3 Jaws 6)Chuck Spanner 7)Open-ended 8)Change Gear 9)Synchronized counter pulley 10)V-belt 11)Axis case 12)Tool-holder spanner 13)T Allen Key 6 Spanner 8-10/12-14/17-19 Z=45, 50,60,60,65,70 240XL075 0-710, cp10 0-828 Morse:2 ++ ,4 ++ 3, 4, 5, 6, 8 Specifications Ouantity 1 1 1 1 1 1 each 1 each 1 1 1 1 set 1 each 1 each 1 1 1 1 1 1 3
3"
I

Note

(cp125)

\

14)painting can 15)GrossScrewdriver 16)StraightScrewdriver
17) Fuse

1 1 1

3"
8A

I

Surveyor:

1

n..L/

f-~.>~ -; ,,'.

:-:-:'J,,;,-:-,.--,-,~

e:_,-,~,-,-'t~b!,71~/

---,-I_D_a_te_: -=_1_..:...1-,>-< __

~_o8

_

Related Interests

sock.el head

19 20

scraw
Spmdle iop sllde

21

S!id(~Ilearing

22

Bearlng pedestal sr--indle top slkle

25

Le'lêf haoowheel 1015Sllde LéVêf hàndwhécl top $!kl~

27

Ci,lInping 0011rever tlantl\lh~1
Paga 43

28

6.5

Exploded· vlew of cross slíde ,

6.5,1

Spare ptlrts f1St of erosa sllde . .. r.- .
Name

l~
,o..

i"age 44

6.6

E.xploded view of

appron

93

6.6.1 o e,
1

Sp.are parts llst of aeoron
Name
13011.' clamping.flJver

tiS

a

s, •...

üi

s
Ma

!

I

I

o c,
78

tiS

Name
Hexagonal socket heed scrow DJN 912

a
..__

i5

(j)

~

a
88 89 9{) Spring pín DlN 1481 Collar for Illverfeooing Siroke pullev lock nu! Stroke pívot lock nu! ...... ·f· 92 lÕCK

>. •...

(j)

~

~"'2"--C;;~mpil1g 40

~-_.--.----.~.~---j-~~~-~~
... -I--··.. __·~··_,-··~·l-·_···,·~······! ~·....
~'~-r-"""'-,-.~-_ .._ ... ~
72 H<ll1dWtmúi bed slide

lev~;-

M5x25
4x50

.~•.... t-r-....•._.•.._._-_ -

+r- , -t-.•_ •.•__ ._ ••;

Oi! nlpple Appron

2

6mm

79 Thrust bearing'.._. •... --~,· _ .._······_ .... _ ..-t-..··_·-l··.... •.. ··"_·······i ....

n

._..._ ..__..._.,,_..._M.~_-._-.__ .. .
1'1 ,
74

····_~_··! .. ···~·-i .. ··• · •

1

80

Shaft wlth loO\heó

whee·1 DIN 6885·
A3x3x9

UwerhanÓ'A'heel uM s!lde . ~"- . ~-Clamping boHlever
hanô'wheel .

91

81

Fealher key

·f···

·· · ···!

nut

[ ...•

- ._

Thrí;1ad pio DIN 91(5
8

93 94

Guide rall

171,

IOCk. nu!
Hexagonal h,ead scrsw sockst DlN 912

I

Too!hed wheel cornblnation

HeXilSOl'1 n"t. ",;,11. sacuring DIN 985
flexagonal socket head screw DlN 912 Scale colfar handwMel bedsllde 2

Me
M12x4ü

M6x1G

í---.~-~~,'~,-~,~ •.. ~,,,.-.~.~.·_.,'+-,.,..,.. .... ... I··.. ,. _ _j 76 71 Retillning ,Ing Bearing pedesl!ll
OIN 471· 14x1

95

Hexagonal socket head screw DlN 912 Hexagonnut

MSx40

M5

97 98

s,'1eeJ naU Sprlng

Page 45

6.7

Exploded view of lathe bed

228
229 \

~~

----221

23

Pagi; 46

·~~'-

6.1.1

Spare parts

~I'fst lathe 01

bed
o c..
!li

Name
AUenscrew

6
1

I
I

.':
';:-.

Handwheel

17 18 19

Nu! Se!screw Gradualeá oollar oftailstock

!

i

20
21
22

Handle

!

I
NUl

I

Wa.sl1er
TaUstock Tallslock moent-

23 24

ing piare
Se! screw ($tud
boll) Clamping

2
....... __

._---_.)

i

plalta

·-1-----------·1I
i

I
Nu! 2

4QOV

i

. ;t~:-:;·-·
~:!•• ~

2;lOV

--------~!.--1--.--~ ____ w_~_h_e_r I~~·· __ ... ._ _
2
I

i

Rack

paga 47

6.8

Exploded view of feed gear

c
399

/

I

A

319

/

-,

242

6.8.1
!IÍ Q.

Spare parts íist of feed gear

O

Nama
012

!IÍ Q.

O

Name
Plate
Gearfôfk.

l:>-

lã !

,êi)

;!t.

40 41"

2

3
4 Shaft C O.ring

2

5

18gg12 I
•• ••

1

L--

I

42

Selector swítch marklng

I

2

6
__ o .••• ------~

Geal'iVhee'---r-T
Featharkey

7

1 I

-··,--1 -1
_-.--••

4 x 30

11
12 13 14

......... SeI screw for ouUel Set screw for chargíng.hQle Screw Screw Flange Bearíng (jea.lwtmel

_-------_._._--

Gllar whú!}! box

ZG$/8
ZG3!8
M()x10 M()X10

15 16 17
18

180202

19 20 21 22 23
24

Shaft

1215

-------Geilt\Vtleel

Shatt ring

__-_
..

.......,...

..,---_.
Clrcl1p

Feather

key

Ll:lflg·lace plnl,on

Featherkey
26 Lock wasnsr

27 28 29

----

Gearwheel Bearing

Flange covor of

leadscrew

31 32 33 34 35

37

Pin

38

O-rlng
$haft 2

~"age 49

6.9

Exploded vlew of headstock
401 .--/ .. 402
,i'!.T

403

419

1426 427 . \
'iP-

l.,~_\
..
4~8

429 ,

ft .-' ~.~

~"O

í/.:J \

.·~·wfl:..J

....

437···· ~

~r
439

430<'-. ~.,. 431 ~
432

.. ~

44Ó

page 50

6.9.1

Spare parts list of headstock
til

o c,
I

Name

51!
_-''' -"14:-1 O
..j

:>.1

I

IlIi I
i O

I o. I
!
I 26

.

Narne
Bi,laring ,

__-r--;:_ .._ -._-_._.".-:+ .. .._ 2.

I

I
I

Charaoterísücs pta\é
Fasteolng screws

i 1-----1
18(J101

I

4 2

[3."r" Pf~;~~~:~~~~Of .
.. 51--' ·_--~+_··~j-_·"···_·,-"--"~·-i
4

I
I I

I

Nu!

4

M10

r.. T.. ·.. _..
28..
29

n. I
27

Comolnaton

01 syn·

chronous I:YeIt ul1ey p anil V-belt pulley

·$ .. .... ~;;.-;-·_ ·_-_ ..
Wi'lsher 1

-I-~' ... - --1

" I
I

01<,5,32

(+ 0,12 f-(}) 84 teeth

I

i

~..,...

••,.."",, . .•. ~""="'~_.~.- ."."""""""""'''''''''''''''''' .="""'"'.,. .. '."'-.'''=''''''-.'-.''''''''''=''''''''''''''

!
V-bel! pu!ley cornblna ..
tíon

028..6 (+ D,07 J -O)
18 teeth

Drlven shatt of motor

s

Bear1ng 31

10
11

----~. -~
.. _.

32
M10

Nu!.
wasner

34

i

wasnsr =_.==~--=-j
Al!en screw

... ~ ....Jl=~=-·--

12

lU

~·36!E- ..C-ce-~-I~'-I~-P-~~-'";-~-;-f-lb-.n..

+-,-ll'..~.. ·_·

1

~_._."==-

13 14 15 15

-Screw
Beilring R.ing Bu~h
200710SE

3"/

Shali of tensionpuiley

I

UI
i

..
~earing~_

L~:_.{
I ' I 39 IL__ j

......J_~._. ~~~
•. ~~. __ ~_I

I
Tenston pune)'

I
22

40

i

Clrclip 1

------

I
--_._---,Spring w8she~
24 Driven $haft of motor

I"
Gates 230XL

Pml{Jctlve cover af tleadstock

I

25

svncnronous heI!
i

1
i
'

I !_._~. ~l

x ·i5

paga 51

Pag~ 52

6.10.1
'!!J

Spare parts list ofchanqe ~ ,..., ..."

gear

-_._-.....-----_.~-"_.:---.----~-_ ....,
~
Nams

-

<li N

(j3

503

Change

Qê&í

ra5!

235rnm

i

I
;

504

I

8f:afing ~:relje~t"31 é'h:ang::::: g2af râii

~-_.~---.l--.--.----.-.-.---.j

i--' h~:i~~~:~: ~~~~~1t~--'--;--+--~~:-1~--~
). so.2-t--·-~-~·~~·---·-·------'-T--·'-·-f-·······65-t;;;h'-'1

I'

'.

mCJ[juie 1,.5

:

i,"""'-'·.: ..

·=··;·-······-····-··-----=~,,~!
BD ;"eU""
rnod lj!·2 1: 5 7ô ~üeth,

~---,-,--i..-- __.

.. _ .__ _ .

moch~i~ 1~5

ro teeth.
506
rnçJc:hm:~ t. '5
65 t~!0th. rtj{)rJu!e 1,5-

charqe

gi;~.\: r=Bmrn. Pi=1Am.m

(-/J

!eelh,

ITIDdlJ!e 1.5

L_~_,J.~m~,_
Q.

;

:

50 \eeth.,
_ó,_ul~e~l,:~.~ ...

4G íeeth. module 1,5

~----~._----_ ..._-~
G'lorJ:J!e

30 iBelh. moduI81:.0

25 teeth, ~! ,S

521

2

521

.incking wnshcr

2

Page 5:~

:~1

6.11

.~
:,1"1 .;':...

f~ ·--r:-:~,- ~;o~" c:~~~ Wiríng diaqram

TURNER280220V-240V
n

r

-J- -- - ~-~ 1--s---T----6-·r--7--.::-T~o)

s:-~ [)) O'
r)

:!,
~
.._-----

.1:)
~

.'

iN I!

-----------_ PE'-"======~=================~====~====='---'--'-'--'-'-'-'---~=~~==~======~====.:~==~.~======= (õi Ç(~J

.:
I I

õl ()
r-,L;-),;(~ m
I!I

·-l
_j

O

(fi

::r

. ~

\d

q6

\

d8

01
'I

~

.

1- 9"l
I
o~ o

_J
- -..

o·····iú·······:······-_··--··························............. ..-

r---I=B------;====~~-=~-=~-±. - =-}l_ I
.J ;

-1

-.-.---.-

Chançe-over R/L

switch

I
.

k
,

Z2

Ul

Uc

M)

6;~l J I
1 -._~

l

_.-

-

"-.

---

._-_.

[--···-·--·------i~;·~-i~9d -.-.-.--.---.. ia g~~~ .. --.- . [ 2 20 V.=24_~~

]1di·tj()~~rE~~;;.·-·::.=~

~"

!Vlachine & /ools

H
ir---!
I

i
I~
I
(j-I

I
!

--I

I~T'---------11(....
!

I

I
;----------i\.
1

o

I

I I
i

r.
lU>

rii
!

I I I

1

!
!

;-----'''''"' "

r

I I

!-=-~

i.

I 1
!

I .

I

I

I

I I

f,

''

I

I
í.. O;

I
> o
!lJ

I~
!

Irrd

I

!
!

I
!.rI

! I
1

I

L-j
I

I

j >i

UQ:

!: s:

Ol~

",

I

i
I

I i
i
I

i0-JI
i
r

i !

I I I
I~

;
i,

r
!
~

I

.

!~I
1"")
._,_.

L.LJ
.... __ . . _

.
l_'

~

~--.J-.Jzn

6,11
L ~E _=-__

TURNER280Vario
Fuse

Eleclric schematic diagram

AC110V 160Hz

-----.---FE3==J-----~L-

=_--__ __ .

l- -.-

~_._=__------~-.---~7------------.-Magnetíc cont actor

1,Smm2

1--®-~3--..

®I
@I
1

Change over swítch
1-- -----

I@
1_

G)

r
Contad

®

CDCDCDCD:
1.5mm2

____ J
1.5mm 2 Motor l1Kw

Fíner Transformer Spe~~ Induces head
I

O,75mm2
L N PE PE

G S V PE

c=:J--1_ G _~ V
Potenhometer

O.5mm2 green ellow red

P1 P2 P3

L1

L2 Control board
A+

A-

,

->

()

7
7.1

Anomalies
Anomalies in the lathe
Problern ._--------_._-;_._._----I Cause f possible effects

! Solutlon

~~=~~~J~f~~~:::::c;:~e:~~-~
j Surface of workpiece rough

i
i!

toa

i.

Tool

blunt

Tool sprinçs Feed too hígh

Resharpen tool Clamptool with lessoverhanq Reducefeed

IH-H_' . . ... ! Workpiece is becomíng

I I !

Radius

at the tool

tip

to little (taüstock

lncrease

radius

Cenlres

are not aliqned

Adjusttallstock Align top
i

to lhe centre
well

coned

iI

has offsst) ' Top síide not aligned well (cutting

stíde
feed

with lhe top slide)

~
r-i

Lathe is chatíerinq

.

._______!

I•

~-_·_··-·--·---------·----i
Reduce ._'_H_av_e the main bearing readjUste~-1

Feed too hlgh

(' have clearance

Maio bearíngs

i Centre runs hot

I'

!
!

Workpieee

has

expancec

!'
i

Loosen taüstock tip

-li-O-O-I h-a-s-a-s-h-o-rt-e-d-g-e-I-íf-e-.·.··-tt-· ·_-G-u-tr-!n-g-s-pe-ed~to--O-h-i9-h-~~~-tI-.-····-R-e-du-e-;e-e-u-tt-ín-g-S-p-ee-d-------1!
Crossf.eed lnsufflclent toa high cooling
..•

Lower crossfeed/smooth

frnish

(allowance no! over 0.5 rnrn) More coolant
i· íncrease Correct clearance angle of the

~.~-~~

...•.......•.•..•...... .:,;""",,-~"""""'--r--"~" ~~ _. -_...

_ ...•...•..•••.. _.-"-"'-'---~

Flank wear toa high

I
1 I

!.
1'

Clearance

angle

toa srnall (tool
to centre

"pushes")
Tool tip height Wedgeangle toosmall

n01 adjusted

I

I
I
i

1.

height adjustment

tool
íncrease wedge angle

i

Cutting edge breaks.off

j •

(heat bulld-


[ •

u~

I
I I

Grinóing

crack due to wrong 0001-

Cool unitcrrníy
Have the císarance in the spindle
bearing arrangemenl readjusted

ln9

i

Excessiva clearance in the spindle bearing arrangement (vibratíons)

Cut thread is wrong

Tool is clamped íneorrectly ar has been started grinding the wrong way
Wrong Wrong pítch diameter

Adjust tool to the Gantre- Grind
angle correctíy

AdjUst the right pitch

! .__

.w ••.•.. w ••••

.w •••

•.•

_w.••_ ••_._.w. __.. _, __

.. _.._w._..... _.

~..

W".

•• __ •__ ••

_J. ~~~~'"~~_~~~w~~~_~t,~~~e2~:'" __ ,'"

i

10 a previous

step, turn the work-

8
8. 1

Appendix
Copyright
©2005
This document is copyríght Ali derived ríghts are also reserved, especlally íhose of translatíon, re-printlng, use of figures, broadcast, reproductíon by photo-mecnanícat or similar means and recording tn data processínç systems, whether partia' or total. The cornpany reserves the right to rnake technícaí alteratlons without prior notlce.

8. 2

Terminology/Glossary
Term Headstock Explanation Housing for the feed gear and thesynchronous belt pulleys Split nut whích ençapes ln lhe leadscew Clamping tool for holding the workpiece Device for holding tne bit Slide on the slideway of the machine bed which feeds parallel to the tool axís Slide on the fathe saddle whích moves transversely to the tool axís Swivelling slide tre Tool Workpiece Taílstock Rest Cutting tool, btt, ate. Plece to be turned or machined Movable turníng aid FoHow ar steady support for turning lon9 warkpieces Device ar clamping aid for driving pieces to be tumed between centres
ali

Leadscrsw nut Lathe chuck Drill chuck Lathe saddle

Cross slide

Top slida
Taper rnandrel

the cross slide

Taper of the blt, the dnllchuckor

the cen-

Lathe dog

..:

Pag..; 57

8. 3

Product follow ..up
We are required to perform a follow-up servíce for our products which extenos oeyond shíp-

ment.
We would be grafeful íf you could send us the foHowing information: • Modified settings

• •

Experiences wíth the lathe, whích could be important to other users Recurring failures

No

Objectof testing

Drawing

Permíssib.le

Measured

[mm]
1--:

[mm]
A: t>.c>v~ B:
().~c»

~B ;,

A: 0,009 B: 0,009

Run-out oi I
spindle .and períodical radial slip ot spindle ,

aI--

~A

r'--l
I

I

I--

d
L-

0,009

,

GI--

2

Run-outof spindle nose

0.0"

.r

r~
I

I

.'

f-

Run-oui ot 3
intemal taper of spíndle

G-

II II

9'
A

A: 0,015

A: ".OlJS B:
0.02.

=1-

B:O,03

'-

1
II

I
I

4

Paraflelism of taílstock guide A = in the vertical plane B:= ln the horizontal plane

n +.
~ 50 !E-

A&
._-

I

A: 0,025/50 8: 0,015150

A: 0·(;>2 B:

·S

OC'°S

11

I
I

I

Page 58

r

9 Test Report
No
Objectof testing Drawíng

Permlsstble

Measured

[mm]
),B

[mm] A:
(;>"t:>v~

;:x

A: 0,009 B: 0,009

f-

1

Run-outof spindle and periodicaf radial slip of spindle
'"1

B: o·~c»

G

..

f-,-~A

r'---l
I

I
f--

d
'-

.

0,009

O2
Run-outof spindle nose

fo·oe>
.r

r~
I
..

I r-

I
II

3

Run-out of interna I taper Qf spindle

G-L-)

9"
T
A

A:.O,015

A: B:

o·o,,!
o·o}.

.-+

B:O,03

I
r::l
I

I

AÓ-o
4
Paraflelism Of taílstock guide A = in the vertical plane B = in the horizontal plane

A: 0,025150

A: o·~2 B:

n
+~ 50 k..,

B ---

B: 0,015150

ocoS

11

I

J

I

Page 58

5

Headstock (fvfT3) and iaílstock (MT 2) centres for same heighl abave reference plane

r-Khfl

Ar ()--D
B'

"

A: (J,03

A:

I~i
HY"

,

'=r

rr-1

.-

I
Parallelism oi spindíe exis with carriage I jmovemem ' I A vertical I plane B horizontal plane

~

I

II

I

I
I

().02-1

A

I I
I
A: 0,03/250

~

A: B:

li

I

-~

6

=

fT I)

1
~

O
250 lE-

--=t~

l~E

0'°5
t>,o~

B: 0,031250

I

I

=

1

i

i

I
1

I

I
0,0/"/75

r
I

1
7

Itop sl:de .wIth
j

II Paralie/1sm. ot
spindle and

~1ll - <q w.1,1
I

I

'--i

cetneçe
movement

I

I
(J,V2.

,

&:-,
1

I

I


I ~

+---+

~

I
0,04

8

I ! I
I
I

Run-out chuck

ot yaw

O
-

D
D
U .
n

I
I
ç.{?~

L
--

Run-out ot yaw 9

I
I
I

chuck Objecl ot testing A: 020mm B: 030mm

~rr
1
~I ~

2 ., <)

A) (j 20mm

A)
1: o-c> 2:

,
!
j I

1: 0,04

I

.2:

O,08i100

o. C' 2o,taL
0'('1

Li

1 .,

1
I
e,

B) 2i 30mm 1: 0,04 2: 0,08/100

B)
1: 2:

I

I

I
Inspector:

~

Date: 12
Page 59

a) Damages ot tecquer

o

a) Connection and functíon b) Funetion emergeney bush button

o o

b) Rust damage

o o
o

c) Identificatian plate data correet/y, comp/ete/y

c) Connection points in lhe
engine terminal box attracted

o
o

d) Transporidamages

d) Motor clockwise left hand motíon

rotetion,

a) CE sign
b) 3-yaw chuck

D
Q
Q

O O O O

.a) Drive belt tension

Qt

O
O

.b) Top siide taper gib clearanee
c) Cross s/ide ieper gib clearanee d) Top slide spind/e c/earanee

I

~

n

c) Quadruple toolholder

O
Q t.......:
r

O

d)Change

gear set

O
Qt

O

€) 2 fixed center and toolbox

O

€) Cross siide spind/e c!e~rance

LV

n
L.

f) Acceptance and lnspection

repor;
!fc~'

Q

O
O O

O

Csmage surfaces cleaned

~

n

O

g) Drehfutterschlüssel Ciiuck Spanner

G

g) SpindJes c/eaned and greased, operation smoothness

G
r ~

O

h) Operating menuei

B

.h) Tellstoct; tunction I wedging

O

a) Quiet running

o
O

Additional parts

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