SUMMIT MACHINE TOOL MANUFACTURING CORP PO BOX 1402 OKLAHOMA CITY, OKLAHOMA 73101

Transcription

1 SUMMIT MACHINE TOOL MANUFACTURING CORP PO BOX 1402 OKLAHOMA CITY, OKLAHOMA TEL: (405) (800) FAX: (405) OPERATOR & MAINTENANCE MANUAL 16B, 20B, 24B AND 28B SERIES ENGINE LATHE KEEP FOR FUTURE REFERENCE Model # Serial # Warranty Start Date

2 Thank you for choosing a Summit Lathe. In this Operator and Maintenance Manual you will find all necessary information for its proper installation, operation and maintenance. The operator and the maintenance staff should read this Manual before starting the lathe installation, operation and maintenance, in order that all instructions provided herein are observed. All safety instructions should be strictly followed. The lathe should be used only according to its designation and the technical characteristics specified. Summit Machine Tool Manufacturing Corp. reserves the right to make changes and amendments to this Manual without notice. If you need additional information, please do not hesitate to contact Summit Machine Tool Manufacturing Corp or your local Summit Dealer. Keep the Manual in a safe and handy place. Summit Machine Tool Mfg. Corp. P.O. Box 1402 Oklahoma City, OK (800) BSeries_manual_rev docx Page 2 of 70

3 C O N T E N T S 1. MACHINE DOCUMENTATION MACHINE DATA PACKING LIST TECHNICAL DATA ELECTRICAL SCHEMATICS MACHINE SAFETY OPERATIONS SAFETY INSTRUCTIONS AND PLATES WARNING ATTENTION! SIGN WARNING! SIGN ELECTRICAL DANGER WARNING PLATE - DIRECTION OF THE SPINDLE TRAVEL WARNING PLATE FOR SWITCHING OF THE FEED-GEAR BOX HANDLE WARNING PLATE FOR SWITCHING OF THE RPM RANGES SAFE OPERATION INSTRUCTIONS TO THE END USER MACHINE SAFETY DEVICES INSTRUCTIONS FOR SAFE OPERATION AND MAINTENANCE OF THE LATHE INSTRUCTIONS TO THE OPERATOR AND MAINTENANCE STAFF MACHINE INSTALLATION AND PUTTING INTO OPERATION MACHINE PACKING HOISTING AND PLACING OF THE LATHE ON A WOODEN PALLET LIFTING AND HANDLING MACHINE ON WOODEN PALLET HOISTING AND PLACING OF THE LATHE IN THE WOODEN CASE MACHINE UNPACKING PRELIMINARY EXAMINATION MACHINE UNPACKING ON A WOODEN PALLET MACHINE UNPACKING - IN A WOODEN CASE MACHINE CLEANING BUILDING OF A FOUNDATION AND LEVELING FOUNDATION INSTALLATION AND LEVELING PERIODIC INSPECTION OF THE MACHINE LEVELING ELECTRICAL CONNECTIONS INSPECTION OF THE ELECTRICAL COMPONENTS PUTTING THE MACHINE INTO OPERATION LATHE OPERATION GENERAL LATHE DESIGNATION MAIN LATHE PARTS AND CONTROL UNITS SELECTION OF THE SPINDLE ROTATIONAL SPEEDS DRIVE THREAD CUTTING CUTTING OF MULTI-START THREADS INSTALLATION OF THE CHUCK ON THE SPINDLE NOSE COOLANT EQUIPMENT LUBRICATION GENERAL NOTES HEADSTOCK LUBRICATION METHODS OF THE HEADSTOCK LUBRICATION FILLING OF THE HEADSTOCK WITH OIL OIL LEVEL BSeries_manual_rev docx Page 3 of 70

4 OIL LEVEL CHECK-UP AND ADDITIONAL FILLING OIL REPLACEMENT FEED GEAR BOX LUBRICATION METHOD OF THE FEED GEAR-BOX LUBRICATION FEED GEAR-BOX OIL FILLING OIL LEVEL OIL LEVEL CHECKING AND ADDITIONAL FILLING OIL REPLACEMENT APRON, BED GUIDEWAYS, LEADSCREW AND DRIVE SHAFT LUBRICATION METHOD OF LEADSCREW AND DRIVE SHAFT LUBRICATION APRON OIL FILLING OIL LEVEL CHECKING OF THE OIL LEVEL AND ADDITIONAL FILLING OIL REPLACEMENT LUBRICATION OF LEADSCREW AND FEED SHAFT LUBRICATION OF THE SADDLE, COMPOUND AND CROSS SLIDE LUBRICATION OF THE CROSS SLIDE DIAL TAILSTOCK LUBRICATION QUADRANT LUBRICATION RECOMMENDED OILS AND GREASES LATHE MAINTENANCE LATHE LUBRICATION ADJUSTMENTS DISC CLUTCHES FOR FORWARD AND REVERSE ROTATION ADJUSTMENT OF THE BELT BRAKE ADJUSTMENT OF THE APRON SAFETY MECHANISM ADJUSTMENT OF THE CROSS SCREW AND THE NUT OF THE LOWER APRON ADJUSTMENT OF THE SAFETY HANDWHEEL ADJUSTMENT OF CLEARANCE BETWEEN LEADSCREW AND HALF NUT ADJUSTMENT OF CLEARANCE FROM THE SIDE OF THE GUIDEWAYS ADJUSTMENT OF CLEARANCE BETWEEN THE COMPOUND SCREW & NUT ADJUSTMENT OF CLEARANCE BETWEEN THE CROSS SLIDE & CARRIAGE CROSS DISPLACEMENT OF THE TAILSTOCK ADJUSTMENT OF THE LEADSCREW AXLE GAP REPLACMENT OF THE SAFETY CUT-OFF SHEAR PIN OF THE LEADSCREW ADJUSTMENT OF THE MAIN DRIVE BELTS ELECTRICAL EQUIPMENT GENERAL SHORTING AND LOAD PROTECTION MEASURES OTHER SAFETY MEASURES MAINTENANCE INSPECTIONS PROTOCOL OF MACHINE GEOMETRICAL ACCURACY PRELIMINARY EXAMINATIONS GEOMETRICAL TESTS PRACTICAL TESTS INCLUDED ACCESSORIES CARRIAGE STOP-LIMITER TAPER FACEPLATES/CHUCKS STEADY REST AND FOLLOW REST BSeries_manual_rev docx Page 4 of 70

5 1. MACHINE DOCUMENTATION 1.1 MACHINE DATA Remark: The sign in the right column shows the lathe version Model: Distance between centers: Inches Serial : Year of production: Version: Metric Inch Inch / Metric H/CE / Spindle front end: ISO702-III-1975(F) DIN USAS B5.9D1 (Camlock version) ISO702-II-1975 (E) No.8 No.11 D1-8 D Power supply 3 х... V +5%,... Hz + 5% Installed capacity... kva Main electrical motor... kw... V...r.p.m BSeries_manual_rev docx Page 5 of 70

6 1.2 PACKING LIST Model: Serial No.: Year: Remark: The sign in the left column shows the lathe version, supplied with the standard equipment and the related auxiliaries. The sign in the box in the end right column shows that the relative position is given in the packing box. Item Description No. Remarks MACHINE STANDARD EQUIPMENT V kw Hz,...r.p.m Electrical installation set with electrical cabinet and 1 control panel V-belts for the main drive: L i L i L i L i L i Chuck safety guard Rear safety guard, non-replaceable Coolant system with motor pump, complete Carriage four-direction rapid traverse unit with 1 electrical motor... V... kw..hz..r.p.m Work light Change gear Z=57 1 in the box Set of leveling bolts, shims and foundation bolts 1 in the box Dead Center Моrse 6 1 in the box Моrse 5 1 in the box Reducing Sleeve: Мetric 80/ Мorse 5 1 in the box Меtric 120/ Моrse 6 1 in the box Мetric 107,5/Мorse 5 1 in the box Camlock key 1 in the box Pin for quill of tailstock 2 in the box Operator & Maintenance Manual (this manual) BSeries_manual_rev docx Page 6 of 70

7 Item Description No. Remarks Carriage stop-limiter Electrical equipment documentation 1 ACCESSORIES Independent four-jaw chuck 15-3/4 16 Lathe Independent four-jaw chuck 19-5/8 20 Lathe Independent four-jaw chuck 23-5/ Lathe Safety drive pulleys for lathe dogs: Size 8 (acc.din, ISO, USAS) Size 11 (acc.din, ISO, USAS ) Set of bolts and nuts (positions available at 1 in the box request:1.2.30, , , ) Dogs: 20; 30; 40; 50; 60; 80; in the box Arbor Моrse 5 for piercing chuck 20 mm 1 in the box Rotating center Morse 5 for tailstock 1 in the box Follow Rest: ½ 7-7/ Steady Rest: Standard: Series - ½ 6 1/ Series 3/4 7 ¾ Extra Capacity: 20 Series Series - 7 ¾ 16 ¾ Roller Tips for Steady Rest 3 in the box Longitudinal stop-limiter Pin for longitudinal stop-limiter 1 in the box Taper 10 х Thread Cutting Dial Universal self-centering three-jaw chuck: Jaw 16 Lathe Jaw 20, 24 & 28 Lathe RECOMMENDED SPARE PARTS Shoe for multi-disk clutch 1 in the box Safety shear pins for leadscrew 2 in the box BSeries_manual_rev docx Page 7 of 70

8 1.3 TECHNICAL DATA Parameter Unit Swing over bed mm inch / ½ Center line height over floor mm inch ½ 46 ½ 47 7/ N/A N/A mm N/A Distance between centers N/A N/A inch N/A Width of bed mm inch 15 ¾ 15 ¾ 15 ¾ 15 ¾ Sound pressure level DIN Teil 1 db(a) Swing over cross slide mm inch 9 3/8 11 7/ /8 Bar capacity mm inch 2 15/ Swing in gap mm inch 25 1/8 27 5/ ½ Replaceable follow rest mm inch 19/ /64 ½ - 7 7/8 ½ - 7 7/8 ½ - 7 7/8 Steady rest Standard mm inch ½ 6 1/8 ½ 6 1/8 ¾ 7 ¾ ¾ 7 ¾ Steady rest Large mm inch 5 1/ ½ 13 ½ 7 ¾ 16 ¾ Effective length in gap with face-plate: mm inch 8 3/8 8 3/8 8 3/8 8 3/8 Spindle nose acc. to ISO702-II/USAS B5.9D1 ISO702-III/DIN D1-8 D1-8 D1-8 D Spindle bore diameter mm inch 3 4 1/8 4 1/8 4 1/8 Spindle taper diameter Metric 80 Metric 120 Metric 120 Metric 120 Front bearing diameter mm inch 4 23/32 5 1/2 6 19/ /64 Self-centering three-jaw chuck mm Spindle speeds Number Spindle speed range r.p.m Main motor power HP Main electrical motor rotation speed r.p.m Power of rapid traverse motor HP ¾ ¾ ¾ ¾ Rapid traverse motor speed r.p.m Coolant pump motor power HP 1/10 1/10 1/10 1/10 Coolant pump motor speed r.p.m Spindle speed to reach full horsepower r.p.m Maximum spindle torque dan.m Maximum tractive force of the feed mechanism dan.m Number of feeds Metric version mm/rev Inch version Inch/rev Longitudinal and cross feeds ratio: 2/1 2/1 2/1 2/1 Rapid Traverse Rate (Longitudinal) mm/min inch/min / / / /32 Rpaid Traverse Rate (Cross) mm/min цол/мин 73 11/ / / /16 Leadscrew Diameter/pitch mm x mm 50x12 50x12 50x12 50x12 mm x inch 2 / 2TPI 2 / 2TPI 2 / 2TPI 2 / 2TPI BSeries_manual_rev docx Page 8 of 70

9 Parameter Unit Number of threads: Metric mm Inch l/inch 60-1/4 60-1/4 60-1/4 60-1/4 Module mm 0, , , , D.P. T/ Cross-slide travel mm inch 11 3/8 11 3/8 11 3/8 15 ¼ Maximum travel of top slide mm inch 5 3/8 5 3/8 5 3/8 5 3/8 Largest rotation angle C degree ±90 ±90 ±90 ±90 Tool bed height from centre line mm inch 1 7/16 2 5/16 2 5/16 2 5/16 Maximum cutter size: / height x width/ mm 25x25 25x25 25x25 25x25 inch 1 x1 1 x1 1 x1 1 x1 Tailstock quill diameter Мм цол 2 15/ / / /16 Tailstock quill taper Моrse 5 Моrse 5 Моrse 5 Моrse 5 Tailstock quill stroke mm inch 9 1/2 9 1/2 9 1/2 9 1/2 Tailstock Offset mm ±10 ±10 ±10 ±10 inch ±3/8 ±3/8 ±3/8 ±3/8 Taper attachment maximum working length mm inch 15 3/4 15 3/4 15 3/4 15 3/4 Maximum taper degree Overall Length mm / 40 inch mm inch mm / 60 inch mm inch mm / 80 inch mm inch mm / 120 inch mm inch mm / 160 inch mm inch Overall Width mm Overall Height inch mm inch Weight mm / 40 Inch kg mm / 60 inch kg mm / 80inch kg mm / 120 inch kg mm / 160 inch kg BSeries_manual_rev docx Page 9 of 70

10 1.4 ELECTRICAL SCHEMATICS BSeries_manual_rev docx Page 10 of 70

11 BSeries_manual_rev docx Page 11 of 70

12 2 MACHINE SAFETY OPERATIONS Warning: The lathe has driving parts and electrical components, which, if the safety measures are not strictly observed, could cause serious injuries and damages. 2.1 SAFETY INSTRUCTIONS AND PLATES WARNING ATTENTION! The word Attention! defined in this Operator & Maintenance Manual is put before every explanation or instruction, the non-observation of which could cause damage to the operators, machine or surrounding environment SIGN WARNING! Meaning: This sign indicates the dangerous locations on the lathe SIGN ELECTRICAL DANGER Meaning: This sign indicates the places on the lathe where dangerous electrical components are located BSeries_manual_rev docx Page 12 of 70

13 2.1.4 WARNING PLATE - DIRECTION OF THE SPINDLE TRAVEL Meaning : If the handle is at the top position, the spindle will go in counter-clockwise direction If the handle is at lower position, the spindle will go in clockwise direction WARNING PLATE FOR SWITCHING OF THE FEED-GEAR BOX HANDLE Meaning: Do not switch the feed-gear box handle at a spindle speed of over 100 rpm! WARNING PLATE FOR SWITCHING OF THE RPM RANGES Meaning: Do not switch the RPM ranges while the spindle is in motion! BSeries_manual_rev docx Page 13 of 70

14 2.2 SAFE OPERATION INSTRUCTIONS TO THE END USER MACHINE SAFETY DEVICES The lathe is supplied with the following safety equipment: Carriage slide stop-limiter Used to switch-off the longitudinal slide, upon touching the apron box. Mechanical slide switch-off device Used to switch-off the automated longitudinal and traverse slide feed upon touching the final stop or in case of overloading. Safety cut-off shear pin of the leadscrew Used in case of equipment overloading. SAFETY SHIELDS: Rear splash guard. Used to prevent accidental access to the lathe working zone. Shield on the leadscrew and drive shaft (version СЕ ). Used to prevent accidental access to the leadscrew and drive shaft. Shield on the universal chuck (with pull-up safety micro-switch). Used to prevent dangerous access to the rotating chuck, faceplate and drive pulley. Upon opening of the chuck guard, the pull-up micro-switch automatically stops. SAFETY MICRO-SWITCHES: Micro-switch at the door of the Norton or Feed Box. Used for protection from the rotating parts during opening of the norton or feed box. Micro-switch for switching-on the clutch for forward and reverse rotation In case of disconnection of the main power supply, this key protects the lathe against the dangerous start up of the machine operation after restoration of the power supply. EMERGENCY STOP BUTTONS (red mushroom) : Emergency stop on the control panel of the gear box. Emergency stop on the control panel of the apron. They are used ONLY in case of danger BSeries_manual_rev docx Page 14 of 70

15 2.2.2 INSTRUCTIONS FOR SAFE OPERATION AND MAINTENANCE OF THE LATHE Check periodically the condition, placement and functioning of the safety mechanisms. The machine should be put in operation only if all safety devices are functioning properly. Warning! Any removal, changing or alteration of a safety device could create a dangerous situation for the operator, maintenance staff or the surrounding environment. The operator and the maintenance staff should read this Operator & Maintenance Manual before commencement of the work or maintenance. All warnings or signs and plates should be strictly observed. The Operator & Maintenance Manual should be kept in a safe and convenient place for immediate use by the operator and maintenance staff INSTRUCTIONS TO THE OPERATOR AND MAINTENANCE STAFF The operator should be qualified and duly authorized and instructed about the necessary safety measures to be taken, in accordance with local regulations. The technician and electrical repair engineer should have the necessary qualifications on maintenance of metal-cutting machines; they should be duly authorized and instructed regarding safety maintenance measures, in accordance with local regulations. Before starting work, the technician and electrical engineer should read this Operator & Maintenance Manual to get familiar with the safety instructions. The lathe should be used only according to its designation and technical characteristics, and all safety instructions and recommendations, should be strictly observed. Before starting the machine, check that all safety devices are properly fixed and in good condition. Periodic inspections for their proper functioning should also be carried out. If the lathe is to be stopped for any period of time, all necessary measures should be taken, so that the machine will not be unsafe when put back into operation. Tools, devices, in-process materials, cleaning preparations, etc. should be kept only at the places specified for this purpose. They should not be placed on the lathe, inside its bedway or on other places, where they could become a potential source of danger. The working zone around the lathe should be kept clean and tidy. The in-process products, tools, devices, etc., should be kept in such way, so as not to disturb the operator s work or to cause accidents. The in-process products, tools and accessories should be cleaned and be free of any chips and greases. Warning! Prior to fixing and tightening of the half-finished material, which are to be machined, they should be carefully cleaned and made free of grease materials. Warning! Keep the machine working area clean and dry BSeries_manual_rev docx Page 15 of 70

16 lathe. WARNING! Never use compressed air for removal of chips or cleaning of the The machine operator should wear safety work clothes, glasses, hats and shoes. Hair should be hidden under a hat, clothes should be buttoned and shoe laces should be tied properly. Warning! Do Not wear bracelets, rings or other jewelry, which could cause an accident, when near the rotating parts of the lathe. If coolant liquids are used, the manufacturer s instructions should be strictly observed and followed. The workpieces subject to machining, should be properly positioned and tightened, so not to cause accidents during rotation. The manufacturer s instructions should be strictly observed for the tightening devices also. Only methods of cutting, which are not dangerous to the operator as well as to the machine, should be applied. Warning! The application of a center of support at the tailstock is prohibited. It is a very dangerous operation. In case of improper functioning of the machine, the operator should stop it immediately and shall inform his supervisor or an authorized service technician. Warning! The repair of the mechanical or electrical defects by non-trained or nonauthorized persons is prohibited. Warning! Any chips accumulated on the machined workpieces, chuck, tool-holder or other machine parts, should be removed by a suitable tool, shown in Fig Fig Suggested tool for chip removal BSeries_manual_rev docx Page 16 of 70

17 To the end user Not observing the safety instructions of this Operator & Maintenance Manual as well as the improper maintenance of the mechanisms and parts under standard working conditions, could cause damage to the operator, maintenance staff, surrounding environment or machine, which will result in termination of the machine warranty period. The safety instructions given in this Operator & Maintenance Manual shall not replace the local standards or safety norms BSeries_manual_rev docx Page 17 of 70

18 3 MACHINE INSTALLATION AND PUTTING INTO OPERATION 3.1 MACHINE PACKING Upon arrival of the machine at the site, the packaging condition and the content described in the order form and the packing list, should be checked (Item 1.2) HOISTING AND PLACING OF THE LATHE ON A WOODEN PALLET Warning! The capacity of the hoisting facilities should correspond to the lathe s weight. Shocks or impacts to the machine, should be avoided. Table 3-1. Approximate gross weight of the machine placed on the wooden pallet. Model D.B.C. (inch) Weight (lbs) Weight (lbs) Weight (lbs) Weight (lbs) 40 5, ,050 6,800 7,000 7, ,380 7,200 7,400 7, ,800 8,000 8, ,500 8,700 9,000 Ст45; C45 L inch L 1 L 2 (D.B.C) Fig Hoisting and positioning of the machine on a wooden pallet BSeries_manual_rev docx Page 18 of 70

19 3.1.2 LIFTING AND HANDLING MACHINE ON WOODEN PALLET The lathe shall be lifted and moved by a crane, or other hoisting facility, equipped with ropes or belts, suitable for handling of machines with such weight. Bars of mild steel (St45, S45) with a diameter of 2 inches should be inserted through the lathe s legs. The length of the bars should be longer than the width of the lathe s legs. It should be determined that all movable parts are properly tightened. The tailstock should be tightened at the end rear position of the bedway. The steady rest should be tightened by the tailstock. The carriage should be positioned in the middle of the lathe s bedway, the carriage lock and the half nut should then be engaged. 3.2 HOISTING AND PLACING OF THE LATHE IN THE WOODEN CASE Attention! The hoisting and lifting facilities should correspond to the lathe s weight. The approximate weights are given in the Table 3-2 below. Table 3-2. Approximate gross weight of the machine placed in the wooden case. Model D.B.C. (inch) Weight (lbs) Weight (lbs) Weight (lbs) Weight (lbs) 40 6, ,550 7,800 8,200 8, ,880 8,300 8,800 9, ,700 9,700 9, ,680 10,300 10,500 Fig Lifting and placing the machine in a wooden case Warning! DO NOT STAND UNDER ANY HEAVY LOADS BSeries_manual_rev docx Page 19 of 70

20 3.3 MACHINE UNPACKING PRELIMINARY EXAMINATION Upon arrival of the machine, check the condition of the packaging and the content, as per the customer s order and the packing list (Item 1.2). In case of missing items as a result of transportation, Summit or your local dealer should be notified immediately MACHINE UNPACKING ON A WOODEN PALLET The lathe has been fixed to the wooden pallet by using bolts. The removal of the lathe from the pallet is done by unscrewing and removing the fixing bolts, then the machine can be lifted and moved according to the instructions given in item MACHINE UNPACKING - IN A WOODEN CASE Unpacking of the lathe is carried out in the following way: The upper cover of the case is removed. The wall at the side of the slide (operator s place) is removed. The two side walls (at the front and rear slides) are removed. The rear side wall is removed. After removing the fixing bolts, the lathe is released from the case bedway. Then the machine shall be lifted and moved according to the instructions of item MACHINE CLEANING Before shipment of the machine, all its external non-painted parts are preserved. The anti-corrosion protectant must be removed by using soft rags, soaked in a solvent, such as mineral spirits or aliphatic petroleum solvent. Then the cleaned parts should be thoroughly dried. Abrasive materials, brushes or metal tools should not be used for this purpose, in order not to damage the metal surfaces. The solvent should be kept away from the painted surfaces. Warning! Highly volatile and flammable substances should not be used, since they could be dangerous for the electrical installation or could cause fire. Smoking is prohibited at a distance closer than 40 feet BSeries_manual_rev docx Page 20 of 70

21 3.5 BUILDING OF A FOUNDATION AND LEVELING For trouble free and accurate operation of the lathe a foundation should be installed and the lathe precisely leveled FOUNDATION The foundation shall be built by casting concrete as per the drawing shown on Figure 3-3. The external dotted line indicates the working area, required for the normal machine operation and maintenance. The foundation s depth should be not less than 350mm. The sizes of the holes of the foundation bolts should be 75x75x350mm. If the lathe is to be installed in a place close to other machines, which could cause vibrations or shocks, the foundation should be isolated by a suitable material for this purpose INSTALLATION AND LEVELING After the foundation settlement, the lathe should be installed on it and leveled in the following way: Leveling pads should be positioned by the foundation bolt openings, so that the leveling bolts can be positioned on the pads during the machine installation, and the foundation bolts can be fixed into the foundation openings. A level with an accuracy of 0.02/1000 mm is to be placed on the lathe. The leveling bolts are used for the initial leveling of the machine, according tо DIN 8606, Accuracy check 01. See the Geometric Accuracy Protocol of Item 8 of this Operator & Maintenance Manual. After leveling of the foundation, a mortar in a ratio of 1:3 (cement: sand) and in a quantity large enough to fill the openings of the foundation bolts and the clearance space beneath the lathe s legs is prepared. The openings for the foundation bolts and the clearance beneath the lathe s legs should be filled. Upon the complete cement settlement, the nuts of the foundation bolts should be evenly tightened. The leveling should be once again checked and the leveling bolts should be adjusted. Alternatively, the lathe can be installed directly on an even and stable concrete floor, where the leveling bolts should be positioned on the leveling pads. The lathe should be leveled by using leveling bolts. Thus, the lathe shows a good stability and accuracy of finishing. This method will be suitable if the lathe s position should be often changed BSeries_manual_rev docx Page 21 of 70

22 The dashed line indicates the working zone 16, and 28 * A B C D Warning : All dimensions are in mm * Distance between the centers Fig Foundation lay-out BSeries_manual_rev docx Page 22 of 70

23 3.5.3 PERIODIC INSPECTION OF THE MACHINE LEVELING The machine should be checked in a longitudinal and cross direction and adjusted, if required, as follows: Every 3 months after the installation of the lathe on the foundation Every month if the machine has been installed on the floor Remark: The proper sub-structuring and leveling of the lathe is an important precondition for the accurate functioning of the machine. 3.6 ELECTRICAL CONNECTIONS Warning! Connection of the lathe to the mains should be made by a qualified and authorized technician only after reading this Operator & Maintenance Manual. For connection of the lathe to the electrical mains the following should be observed: It should be verified, that the machine electrical data corresponds to those of the mains; The lathe should be connected to the main supply through quick-blow fuses; The connection should be made by using a four-wire bundled cable of the proper size; The cable at the lathe s input should be protected per local electrical code; The lathe should be grounded according to your local electrical code; Before switching on the supply voltage, the condition of the electrical installation, electrical panel, electrical control devices and connections tightening should be carefully examined. After switching on the supply voltage, proper grounding should be checked and eliminated. A functional check of the electrical control devices should be made. The check should be made according to the customer s order, as described in the item BSeries_manual_rev docx Page 23 of 70

24 3.7 INSPECTION OF THE ELECTRICAL COMPONENTS The examination of the electrical components should be carried out in accordance with the principle electrical circuit, as follows: To supply the electrical panel, the main switch QSO is positioned at I. The signal lamp HL, located at the main switch, will light on. The main electrical motor can be activated by using the button SB1, and can be stopped by using the button SB0.1. The motor of the coolant pump can be activated by the double-position ON/OFF switch SB2. Electrical motor for rapid traverse can be activated by pressing the button SB3, and can be stopped by releasing it. The work lamp can be switched on by the switch SB PUTTING THE MACHINE INTO OPERATION At the initial start up of the lathe, after its installation or after a long idle period of time, all machine parts should be carefully inspected and thoroughly cleaned. The level of the oil should be checked in the headstock, carriage and feed gear box. The guideways along the lathe s bedway, carriage slides, tailstock and leadscrew should be carefully lubricated. Procedure of the initial start up: The mechanisms functioning should be checked by hand. The mechanisms should operate easily and without any resistance; All control devices should be checked; The tank should be filled with a suitable coolant liquid, in accordance with item 4.9; The main button of the electrical panel is switched at the position I. The signal lamp goes on, showing that the electrical cabinet is under voltage; The main electrical motor is actuated by using the red button Start on the control panel; Check and make sure that the main electrical motor rotates the belt pulley of the headstock in the counter clockwise direction, as it is marked by the arrow on the belt pulley. If it does not, then interchange two of the incoming phases. After starting the main electrical motor, check the lubrication of the headstock. If the motor is rotating in the proper direction the oil pump will function properly and circulating oil can be seen in the sight glass. For more details see Section 5 Lubrication ; Check the lubrication of the feed box. During the operation of the feed box, the oil-indicating window on the right wall of the box (above the leadscrew) should be poured over by oil. For more details, see Section 5 Lubrication ; BSeries_manual_rev docx Page 24 of 70

25 Check the apron lubrication. When the plunger for the piston pump on the apron box is actuated, oil should appear on the bed guideways. For more details, see Section 5 Lubrication ; Check the headstock drive for different speed ranges; Check that the rapid feed is functioning; Check the coolant installation functioning; After a one-hour machine operation at an idle speed, check the level of the oil in the boxes and add additional oil, if necessary. For more details, see Section 5 Lubrication ; After two working shifts of the machine, the belt tightness of the main drive should be checked and adjusted, if necessary. For more details see Section 6 Machine Maintenance BSeries_manual_rev docx Page 25 of 70

26 4. LATHE OPERATION GENERAL The information in this section is designed for operators trained and authorized for work with universal lathes. LATHE DESIGNATION This lathe is designed for mechanical machining of external and internal rotation surfaces, cutting of metric, inch, module and diametral-pitch threads on workpieces of ferrous, non-ferrous metals and materials. By using the taper attachment, conical surfaces can be machined as well. Warning: The lathe should be used only in accordance with its designation and the technical data, given in item 1.3. Any use of the machine outside these requirements, modification or application of non-original spare parts is dangerous and may result in termination of the lathe warranty period. Safe Operation Warning: The machine is equipped with two emergency stop-buttons. These stop devices should be used ONLY in EMERGENCY situations. Do not use them under ordinary operating conditions BSeries_manual_rev docx Page 26 of 70

27 MAIN LATHE PARTS AND CONTROL UNITS 1. Bed 2. Legs 3. Headstock 4. Feed gear box 5. Apron 6. Carriage 7. Compound 8. Tailstock 9. Belts 10. Control shaft 11. End gears 12. Tool holder (optional) 13. Longitudinal stop 14. End gear cover 15. Chuck guard, Splash guard 16. Steady rest 17. Electrical panel 18. Handle for switching of the left and right thread 19. Control panel 20. Coolant equipment 21. Lighting equipment 22. Control handle for switching-on and off of forward and reverse direction of spindle 23. Handle for selection of coarse and fine thread pitch and feed 24. Handle for selection of spindle speed range 25. Handle for selection of spindle speed range 26. Handle for selection of spindle speed range 27. "Stop" button (emergency button) 28. Handle for selection of leads for feeds or threads (A-D) 29. Handle for selection of leads for feeds or threads (1-8) 30. Handle for switching on and off of the drive shaft or leadscrew 31. Handle for engaging and disengaging the half nut 32. Control lever for longitudinal and cross travels 33. Handwheel for longitudinal feed 34. Handwheel for cross feed 35. Handwheel for movement of the compound 36. Longitudinal travel reading dial 37. Handwheel for tailstock travel 38. Handle for locking of tailstock barrel 39. Handle for locking of tailstock 40. Main switch Lubrication button for the guideways parts 44. Plate for multi-start thread cutting Rapid traverse engagement disengagement button Emergency stop-pedal (not available) BSeries_manual_rev docx Page 27 of 70

28 Figure 4-1. Lathe s main parts and control components BSeries_manual_rev docx Page 28 of 70

29 Figure 4-2. Main parts and control components SELECTION OF THE SPINDLE ROTATIONAL SPEEDS The universal 16, 24 and 28 Series Lathes are equipped with 21 forward and 11 reverse rotational spindle speeds. The universal 20 Series Lathe is equipped with 15 forward and 8 reverse rotational spindle speeds. The rotational speed range of the 16 thru 28 lathes is given on Figures 4-3, 4-4, 4-5 and 4-6. The selection of the rotational speed for the 16, 24 & 28 Series Lathes is made by handles 24, 25 and 26. Selection of the rotational speed range for the 20 Series Lathe is made by handles 24 and 25. The disc, shown on Figure 4-3 and Figure 4-5, located on the front part of the headstock and being operated by handle 24, shown on Figure 4-1, has four fixed positions. The sector of the disc, where the required rotational speed is selected, should be positioned at the left and at the right side of the vertical line, depending on where the fixed position of the disc is located. The pointer is directed to the required sector by handle 26, shown on Figure 4-2, having two fixed positions. NOTE: On the 20 Series Lathe, the sector of the required rotational speeds, shown on Figure 4-4, can be positioned against the arrow of the plate BSeries_manual_rev docx Page 29 of 70

30 The hub, shown on Figure 4-6, operating the handle 25, shown on Figure 4-1, has three color indications (green, red and blue). The color of the background of the required rotational speed is positioned against the arrow of the plate. Starting and stopping the spindle for forward and reverse directions is made by handle 22, shown on Figure 4-1. Warning: Changing of the spindle rotation speed should be made ONLY after the spindle has been stopped. Changing the spindle speed while rotating could cause serious damage to the headstock, which may void the warranty. DRIVE The feed gear box of the lathe, used for feeding and threading purposes, consists of: Mechanism for coarse and fine pitch, left- and right-hand thread: It is located on the headstock position 23, Figure 4.2, and can be adjusted by using handles at positions 23 and 18; Gear quadrant Figure 4-2 position 11: It can be adjusted by moving the lowest gear block, according to Figure 4-7, or the plate, fixed on the front part of the headstock; Feed gear box position 4, Figure 4.1: It can be adjusted by using handles 28 and 29 for select the required pitch of the thread or feed, and handle 30 for selecting the type of thread (metric or inch) and feed; BSeries_manual_rev docx Page 30 of 70

31 BSeries_manual_rev docx Page 31 of 70

32 24 & 28 Series Fig BSeries_manual_rev docx Page 32 of 70

33 Carriage: The actuation and stopping of the longitudinal and cross feed of the carriage is done by handle 32, Figure 4-1. The direction of travel corresponds to the direction of the handle. The carriage travel during the threading operation is carried out by the leadscrew and half nut. Engaging of the half nut is made by handle 31, Figure 4-1. A protection is ensured between the handle for starting of the automatic feeds and those for engaging of the half nut, which prevents simultaneous operations. The carriage functioning with the nut being engaged is made by using the handles 22, Figure 4-1. In addition to the feed mechanism, the carriage is equipped with a rapid traverse device. Actuation of the rapid traverse direction is selected by handle 32, Figure 4-1 for automatic feed. The button 41, Figure 4-2 is pressed for starting the rapid traverse motor. The carriage is equipped with an override clutch, which ensures the activation of the carriage rapid traverse with or without the feed box being engaged. THREAD CUTTING The machine can be adjusted for cutting of threads of metric, inch, module and diametral-pitch, as shown on the front plate (Figure 4.7). Procedure: Set the spindle speeds with handles 24, 25 and 26, (20 uses only handles 24 and 25), Figure 4-1, and according to the thread chart; Select coarse or fine thread pitch with handle 23, Figure 4-2; Select left or right hand thread with handle 18, Figure 4-2; Adjust the lowest gear block of the quadrant position 11, Figure 4-2, as per the thread chart; Set handle 28, Figure 4-1, as per the thread chart (A; B; C; D) Set handle 29, Figure 4-1, as per the thread chart (1, 2, 3, 4, 5, 6, 7, 8); Set the thread type by using handle 30, Figure 4-1 (metric or inch); Use handle 31, Figure 4-1, to engage the half nuts; In addition to the threads in the thread chart, three additional thread pitches are shown (19, 27, 11-1/2 TPI), that can be cut as stated above and with additional end gears BSeries_manual_rev docx Page 33 of 70

34 CUTTING OF MULTI-START THREADS Procedure: Adjust the feed mechanism, with the feed being equal to the thread pitch, multiplied by the number of thread leads, according to item 4.6; Cut the first thread lead; By using the belt pulley, turn the spindle by hand in such way, so that the figure 0 of the plate 44, Figure 4-2, comes against the pointer; Place handle 18, Figure 4-2 in a neutral position; Turn the spindle in the direction, shown on plate 44, till the figure correspondent to the required number of the thread leads, comes against the flange mark; Move handle 18, Figure 4-2 to previous position; Repeat the procedures described in item 3 to 7, till all thread lead are cut; Warning: Do not change the speed during cutting multi-start threads BSeries_manual_rev docx Page 34 of 70

35 Series Figure BSeries_manual_rev docx Page 35 of 70

36 4.8. INSTALLATION OF THE CHUCK ON THE SPINDLE NOSE The cam (2), located radially to the spindle, should be placed in a zero position (the cam and the spindle markings should coincide). The clamping device position 1 should be placed on the spindle taper till the sleeves (4) enter through the spindle bores and till the > lines of the clamping device and spindle coincide (3 to 6 o clock). The dismantle procedure is carried out in a reverse order. Figure 4-12 Warning: Avoid any shocks to the spindle or clamping device during the installation procedure, in order to eliminate the risk of damage. Warning: For the safe operation of the clamping devices never exceed the maximum allowable rotation speed, which is marked on the clamping device or is stated in the manufacturers instruction BSeries_manual_rev docx Page 36 of 70

37 4.9. COOLANT EQUIPMENT Cooling of the cutting zone and of the cutting device is carried out by means of coolant equipment. The coolant is fed by a electrical pump (1), which sucks the coolant liquid from the tank (2) by means of the hose (3) to the flexible pipe, mounted on the carriage. A valve (4) is mounted on the pipe, which controls the required flow. The liquid return is made directly from the tray (5) into the tank (2). The electrical pump is switched on by a two-position switch on the control panel. It is recommended that the pump be switched off when the valve of the coolant equipment is closed. Before and after operation of the coolant equipment clean and lubricate the metal surfaces. Use coolant liquids, which will not cause corrosion of the metal surfaces. If the coolant equipment fails to deliver coolant liquid, or lowers its flow rate sharply, identify and eliminate the cause as soon as possible. The general cause of this fault is the irregular cleaning of the equipment. If the equipment is regularly used, it should be cleaned at least every six months. The tank should be cleaned at least once a week, and the coolant should be regularly controlled. The coolant liquids used should be in conformity with the chosen technology, type of the material being machined and they should not be harmful to the machine operators and surfaces. Hand washing by coolant liquids is prohibited! Figure BSeries_manual_rev docx Page 37 of 70

38 5. LUBRICATION 5.1. GENERAL NOTES Warning: The lathe is supplied by the manufacturer WITH OIL in the headstock, feed gear box and apron. Before putting the machine into operation, the oil level in the headstock, feed gear box and apron should be checked. All other mechanisms should also be greased, in accordance with the instruction of this section, as well as with Table 5-1 and Chart HEADSTOCK LUBRICATION METHODS OF THE HEADSTOCK LUBRICATION The spindle systems, gear transmissions and other mechanisms of the headstock are lubricated automatically by means of a oil gear pump and through splashing. The oil gear pump sucks the oil from the bottom of the headstock though the filter and delivers it to the oil distributor. One part of the oil is fed to the oil-indicating window, through which the operation of the lubrication system can be watched FILLING OF THE HEADSTOCK WITH OIL Lathe model & 28 Quantity 3 ½ gals. 4 gals. 5 gals. Class of oil CL32 acc. DIN51502 or CB32 acc. ISO (See Тable 5-1) OIL LEVEL The oil should be filled up to the middle of the rear oil-indicating window at the upper front part of the headstock OIL LEVEL CHECK-UP AND ADDITIONAL FILLING Each time before starting the machine or minutes after its turning-off, check the oil level at the oil-indicating window. Fill additional quantity up to the middle of the oil-indicating window, if required. Warning: Do not put the machine in motion if the oil is below the middle of the oilindicating window. Overfilling of the gear box with oil should also be avoided BSeries_manual_rev docx Page 38 of 70

39 OIL REPLACEMENT Recommendation: To avoid splashing while draining the oil, a proper chute of iron sheet of 40 inch length, should be made. Hold the chute so that one end is below the drainage hole and the other one above the bowl. The following periods of oil replacement are recommended: First replacement: days from the date of putting the lathe into operation Second replacement: days from the first replacement Routine replacement : Every 2-3 months. Recommendation: Each time the oil is drained, wash the headstock with solvent recommended by the manufacturer of the lubrication oil FEED GEAR BOX LUBRICATION METHOD OF THE FEED GEAR-BOX LUBRICATION The mechanisms of the feed gear box are automatically lubricated by the oil piston pump and through splashing. The oil piston pump sucks the oil from the bottom of the gear box though the filter and delivers it to the oil distributor. One part of the oil is fed to the oilindicating window, located directly at the output of the leadscrew. If circulating oil can be seen at this window, it means that the pump is operating properly and the mechanisms are lubricated FEED GEAR-BOX OIL FILLING Lathe model Type of oil CL32 acc. to DIN51502 or CB32 acc. to ISO (See Table 5-1) Quantity 2 qts. 2 qts. 2 qts. 2 qts OIL LEVEL The oil should be filled up to the middle of the rear oil-indicating window at the lower left part of the gear box OIL LEVEL CHECKING AND ADDITIONAL FILLING Each time before starting the machine or minutes after its turning-off, check the oil level at the oil-indicating window. Fill additional quantity up to the middle of the oil-indicating window, if required. Warning: Do not put the machine in motion if the oil is below the middle level of the oil-indicating window. Overfilling of the gear box with oil should also be avoided BSeries_manual_rev docx Page 39 of 70

40 OIL REPLACEMENT The following period of oil changing are recommended: First replacement: days from the date of putting the lathe into operation Second replacement: days from the first replacement Routine replacement: At every 2-3 months. Recommendation: Each time after the oil is drained, wash the gear box with solvent, recommended by the manufacturer of the lubrication oil APRON, BED GUIDEWAYS, LEADSCREW AND DRIVE SHAFT LUBRICATION METHOD OF LEADSCREW AND DRIVE SHAFT LUBRICATION The mechanisms of the apron are lubricated through oil bath or splashing. The bed guideways, leadscrew and drive shaft are lubricated by using the oil from the apron though piston oil pump, controlled by a button, located at the front apron panel. The lubrication of the bedway, leadscrew and drive shaft is carried out at periodic intervals, as per the Chart APRON OIL FILLING Lathe model Oil type CL32 acc. DIN51502 or CB32 acc. ISO (See Table 5-1) Quantity 2 qts. 2 qts. 2 qts. 2 qts BSeries_manual_rev docx Page 40 of 70

41 OIL LEVEL The oil should be filled up to the middle of the rear oil-indicating window at the lower left part of the gear box CHECKING OF THE OIL LEVEL AND ADDITIONAL FILLING Attention: It should be taken into account that the oil in the apron is used faster, since it is used for lubrication of the apron mechanism as well as for the bed guideways. For this reason the oil level of the apron should be carefully monitored through the oil-level indicating window OIL REPLACEMENT The following periods for oil replacement are recommended: First replacement: days from the beginning of putting the machine into operation. Second replacement: days after the first replacement Routine replacement: At every 2-3 months Recommendation: The exhaust oil should be drained and the apron should be washed out by solvent, as recommended by the company-manufacturer of the lubricant oil LUBRICATION OF LEADSCREW AND FEED SHAFT The bearing beds are filled with grease during the machine installation. The grease should be replaced with new in case of repair or replacement of the bearing LUBRICATION OF THE SADDLE, COMPOUND AND CROSS SLIDE They should be lubricated by the operator every day with oil by means of a oil can, through the respective ball press -feeders, as per the Chart 5-1 and Table LUBRICATION OF THE CROSS SLIDE DIAL The dial should be lubricated at periodical intervals through the press-feeder located on the axle, as per the Chart 5-1 and Table BSeries_manual_rev docx Page 41 of 70

42 5.8. TAILSTOCK LUBRICATION The quill and the screw of the tailstock should be lubricated when used, with oil by means of a oil can, through the respective ball press-feeders, as per the Chart 5-1 and Table QUADRANT LUBRICATION The quadrant gears are lubricated with grease once per month. When operating in tropic climate, the quadrant gears should be lubricated regularly with grease along the whole length to inhibit corrosion BSeries_manual_rev docx Page 42 of 70

43 5.10. RECOMMENDED OILS AND GREASES COMPANY-PRODUCER AND TRADE NAME CLASS MOBIL SHELL ESSO CB 32 ISO MOBIL VACTRA TELLUS OIL 32 TERESSO 32 OIL LIGHT TELLUS OIL C32 NUTO 32 G 68 X M 2 MOBIL VACTRA TONNA OIL T68 FEBIS K68 OIL No. 2 TONNA OIL TX68 ALVANIA BEACON 2 MOBIL PLEX 47 GREASE R2 SUPER ESSO GP GREASE R2 GREASE COMPANY PRODUCER AND TRADE NAME CLASS BRITISH PETROL CASTROL VALVOLINE CB 32 ISO G 68 X M 2 ENERGOL CS32 MAGNA 32 CIR 32 PERFECTO I32 MACCURAT 68 MAGNA BC68 GES 68 ENERGOL GHL68 MAGNA BSX 68 SPHEROL APT2 L2 EP GREASE LTX2 GREASE GREASE LTX2-EP SPHER0L EPL2 COMPANY PRODUCER AND TRADE NAME CLASS Q8 TAMOIL CHEVRON CB 32 ISO VEEDI 32 INDUSTRIAL OIL 32 CIRCULAN OIL 46 GST OIL46 WAGNER TANWAY OIL 68 VISTA OIL 68X G 68 X M 2 REMBRAN P2 TAMILITH GREASE 2 TAMILITH GREASE 2EP DURALITH GREASE EP2 Table 5-1. Recommended oils and greases BSeries_manual_rev docx Page 43 of 70

44 Lay-out 5-1. Lathe lubrication BSeries_manual_rev docx Page 44 of 70

45 6. LATHE MAINTENANCE 6.1. LATHE LUBRICATION Lubrication of the lathe is of great importance for its trouble-fee operation and long life. The lathe lubrication and oil replacement should be strictly done according to the instructions, given in section 5.0 Lathe Lubrication ADJUSTMENTS All machine mechanisms are adjusted and tested by the manufacturer. After a long operation or repair the mechanisms of the lathe should be re-adjusted DISC CLUTCHES FOR FORWARD AND REVERSE ROTATION The double clutch for forward and reverse rotation type Sigma (See Figure 6-1) has two disc sets А and В, located at both sides of the engaging ring (1). The disc set А (nearest to the belt pulley) serves for transmitting the spindles rotation in a counterclockwise direction, the disc set В (outermost from the belt pulley) in a clockwise direction. The clearance between the discs have been adjusted by the manufacturer to ensure the required torque without excessive slippage of the clutch discs. After a long operation, as a result of normal wearing of the discs, the clearance between the disc is to be re-adjusted. Procedure Disconnect the power supply through the main switch from the electrical cabinet; Remove the screw, holding the right side of the electrical cabinet to the machine, and turn the cabinet until it is away from the gear box (ONLY ON 16 SERIES LATHES). A cover on the wall will be seen, through which the clutch can be accessed; Remark: The & 28 SERIES LATHE electrical cabinet is not installed against the lid to allow an access to the clutch. In this case, the cabinet should not be released and turned aside. Remove the 6 screws (6mm hex-cap) from the cover and remove it, allowing access to the clutch. Adjustment of the clearance of the disc sets A (for the spindle right-hand direction) Pull out and rotate at 90 о the tab (2), which fixes the adjusting ring (3) to the compressive disc (4), the adjusting ring (3) being removed from the compressive disc (4); By means of a metal pin 5, which is inserted in one of the adjusting nut openings, turn the nut in the direction towards yourself to eliminate the excessive clearance; BSeries_manual_rev docx Page 45 of 70

46 After eliminating the clearance between the discs, return the tab (2) back at its initial position to fix the adjusting ring (3) to the compressive disc (4). If necessary, rotate by hand the belt pulley, after switching on the clutch to the disc set B ; Warning: Before starting, check and make sure that the tab (2) is placed at its position and that the adjusting ring (3) is fixed to the compressive disc (4). Adjustment control Switch on the main power supply and start the electrical; Check the clutch by switching on the spindle to rotate in the right-hand direction from the control lever, where: - If the control lever was easily actuated and the spindle movement is smooth, it means that the clearance between the disc is within its normal limits; - If the control lever can not be easily actuated and the spindle moves to fast, it means that the discs are excessively tightened, which could cause their rapid wearing out. In such case the excessive compression between the discs should be released by rotating the adjusting ring in the reverse direction. Adjustment of the clearance between the disc set В (for a reverse spindle direction) Proceed in the same way as described for discs set A, but to eliminate the excessive clearance between the disc, the adjusting ring (3) should be turned in the reverse direction (from yourself towards the lathe bedway); А (Forward) В (Reverse) Fig Connector for direct and reverse spindle runs BSeries_manual_rev docx Page 46 of 70

47 ADJUSTMENT OF THE BELT BRAKE The adjustment of the belt brake is made only when the brake cannot stop the spindle within the required time, with the motor being stopped (the control lever is at neutral position), or after replacement of the worn belt brake (See Figure 6-2). Procedure Disconnect the power supply by the main switch on the electrical cabinet; Remove the screw, which fixes the electrical cabinet to the lathe, and turn the cabinet away from the gear box (16, 24 and 28 SERIES LATHES). A cover will appear on the wall, through which the belt brake and clutch for the spindle forward and backward stroke can be accessed. The cover is fixed by 6 screws; Warning: In the 20 SERIES LATHE the electrical cabinet is not installed against this cover to allow access to the clutch. Therefore, the cabinet should not be released and turned aside. Release the counter-nut (1); Tighten the adjusting nut (2) to the required extent to eliminate the excessive clearance between the belt brake (3) and the brake drum (4); Tighten the counter-nut (1) to fully engage the adjusting nut (2). Adjustment control Remove the universal chuck from the spindle to check the following things: When placing the control lever at the neutral position to stop the spindle, rotating at a maximum speed without the chuck, the spindle should stop within 6-7 sec. Warning: Do not over-tighten the brake belt. If the clearance between the brake belt (3) and the brake drum (4) is too small, it may cause excessive wear and overheating BSeries_manual_rev docx Page 47 of 70

48 Figure 6-2. Belt brake adjustment BSeries_manual_rev docx Page 48 of 70

49 ADJUSTMENT OF THE APRON SAFETY MECHANISM The safety mechanism stops the motion of the apron in case of dangerous overloading. The pressure, actuating the safety washer, is caused by the following adjusting nuts (See Figure 6-3): Screw (1) for the longitudinal automatic carriage travel (towards yourselfdirection); Screw (2) for the crosslide automatic travel (away from yourself-direction). Procedure By tightening the adjusting screw (1), the spring (3) is compressed and the effort to disengage the teeth (4) and to discontinue the travel towards the apron, increases. By loosening the screw, the pressure to disengage the teeth (4) is reduced and the travel towards the apron stops. Fig Adjustment of the apron safety pulley BSeries_manual_rev docx Page 49 of 70

50 6.3. ADJUSTMENT OF THE CROSS SCREW AND THE NUT OF THE LOWER APRON Procedure Remove the cover (3) from the lower apron to ensure access to the adjusting nut (1) and counter-nut (2); Release counter-nut (2); Tighten the adjusting nut (1) until the required clearance is obtained; Tighten the counter-nut (2); Close the cover (3). Figure 6-4. Adjustment of the cross screw and nut of the lower apron ADJUSTMENT OF THE SAFETY HANDWHEEL Procedure Remove the cap (10); Release the counter-nut (11) by several revolutions; By means of screwdriver turn in a counter clockwise direction the screw (12) to release the lever system. The safety handwheel should remain engaged at all positions of the lever; Put the lever (1) at a front position to start the automatic cross feed; Tighten the screw (1) in a clockwise direction till the safety handwheel is released. At this position tighten the counter-nut (11) BSeries_manual_rev docx Page 50 of 70

51 Adjustment control Put the lever (1) at a rear position; Through free rotation, check the safety handwheel and make sure that it is not under friction or engagement. If so, then repeat the adjustment procedure as described above. Fig. 6-5А. Adjustment of the safety handwheel Fig. 6-5В. Adjustment of the clearance between the leadscrew and the half nut BSeries_manual_rev docx Page 51 of 70

52 ADJUSTMENT OF CLEARANCE BETWEEN LEADSCREW AND HALF NUT Procedure Release the screw (9), fixing the nut (8) to the hub; The clearance between the leadscrew and half nut will be increased, when the nut goes in a clockwise direction, and if the half nut goes in a counter clock-wise direction, then the clearance between the leadscrew and the half nut is reduced; Tighten the screws (9), upon adjustment of the required clearance; Adjustments check-up With the half nut engaged with the leadscrew, check and make sure that the clearance is equal to half of the graduation mark on the longitudinal dial ADJUSTMENT OF CLEARANCE FROM THE SIDE OF THE GUIDEWAYS Procedure Loosen the screw (1) to release the clamp (2); The plane А of the hub should be adjusted to obtain the required clearance between clamp (2) and the lower plane of the bed guideway, at a tightened position of the clamp (2) by screws (1); Figure 6-6А. Adjustment of the clearance from the side of the V guideway Procedure Release the counter-nut (3); Tighten the nuts (4) to obtain the required clearance between the hub (5) and the lower plane of the bed guideways; BSeries_manual_rev docx Page 52 of 70

53 Tighten the counter-nuts (3) to obtain the required clearance; Fig. 6-6B. Adjustment of the clearance from the side of the flat guideway Adjustment control When the handwheel is turned, the apron should move smoothly and without any difficulties in a longitudinal direction ADJUSTMENT OF CLEARANCE BETWEEN THE COMPOUND SCREW & NUT Procedure The pins (2), which fix the nut (1), should be pressed in a inwards direction until the nut is released, then the nut is to be tightened until it is fixed by the other hole. The second pin should be pressed and the nut to be tightened until fixed by the first one. This procedure shall be repeated until the required clearance in the screw joint is obtained (four mark of the dial). Figure.6-7. Adjustment of the clearance between the screw and the nut of the compound BSeries_manual_rev docx Page 53 of 70

54 ADJUSTMENT OF CLEARANCE BETWEEN THE CROSS SLIDE & CARRIAGE The adjustment of the clearance between the contact surfaces of the cross slide (1) and the carriage (2) is made by means of the gib (3). The clearance between the guideways of the compound and cross slide is adjusted in the same way. Procedure To release the gib (3), loosen the fixing screw (4) from the rear side of the slide; Tighten the screw (5) until the required clearance is obtained; Then fix the gib (3) by tightening the fixing screw (4). Figure 6.8 Adjustment of the clearance between the cross slide and carriage Adjustment control The clearance between the surfaces under friction should be less than 0.03 mm (.0015 ), if checked by gauge; The travel should be smooth and without any difficulties BSeries_manual_rev docx Page 54 of 70

55 CROSS DISPLACEMENT OF THE TAILSTOCK The upper part of the rear saddle (6) is displaced in a cross direction towards its main part (5), if a workpiece with a long conical surface is machined. The displacement value can be read on the scale at the rear tailstock. One mark of the scale corresponds to a displacement of 1mm (.039 ) at the left and right-side of the zero mark. Procedure Release the tailstock by using the lever (1); Loosen the screw (2); By loosening or tightening the screw (3), Figure 6-10, the upper part of the tailstock is displaced towards the front, i.e. to the left or the right-side from the zero mark; After displacement of the tailstock to the required mark, tighten the screw (2). Warning: Upon completion of the work, return the tailstock to its initial position and with an arbor and indicator check the alignment between the tailstock and the headstock. Fig Cross displacement of the tailstock BSeries_manual_rev docx Page 55 of 70

56 Figure Cross displacement of the tailstock BSeries_manual_rev docx Page 56 of 70

57 ADJUSTMENT OF THE LEADSCREW AXLE GAP Procedure Remove the cover from the feed-gear box; By using screwdriver put in an upright direction the tooth of the engaging pulley (2) to release the nut (3) ; By tightening the nut (3), the required tightness at the axial bearings (5), is achieved; Engage the nut (3) by folding the tooth towards the nut wall; Put the cover on the feed gear-box. Fig Adjustment of the axle clearance of the leadscrew Replacement of the safety cut-off shear pin of the leadscrew BSeries_manual_rev docx Page 57 of 70

58 REPLACMENT OF THE SAFETY CUT-OFF SHEAR PIN OF THE LEADSCREW The shear pin (1) of the leadscrew is cut off and the power circuit of the feed gear box is disengaged. In this case the broken pin should be replaced with a new one. Two spare shear pins are supplied. (See Figure 6-11) Procedure Remove the safety wire (4) from the shear pin (1); Pull out the two halves from the shear pin; Then replace the broken pin with a new one and fasten it with the safety wire ADJUSTMENT OF THE MAIN DRIVE BELTS Stretching of the belts of the main drive has been adjusted by the manufacturer. After putting the machine into operation, stretching of the belts should be checked and properly re-adjusted, if required. Re-adjustment is required also after the belts have been replaced. Check the belt stretching every month and adjust it, if required. Warning: It should be taken into account that if one belt is damaged, all other belts should also be replaced. Install the new set of belts by hand. Do not use tools, which could damage them. Procedure: To access the belts remove the cover on the leg beneath the headstock; Slightly loosen bolt (1), which fixes plate (2), on which the motor is mounted: The belt can be properly stretched by unscrewing the lower nut (3) and by screwing the upper nut (4); Warning: Do not over stretch the belts, as it may cause faster wear and overloading of the bearings of the motor and input shaft of the gear box. (1). After adjusting the belt stretching, tighten the installation plate (2) by using bolt Inspection When the machine runs at high speed, the belts should not slip and an abnormal noise should not be heard; BSeries_manual_rev docx Page 58 of 70

59 Fig Tightness of the main drive belts adjustment BSeries_manual_rev docx Page 59 of 70

60 7. ELECTRICAL EQUIPMENT 7.1. GENERAL The machine is equipped with a main motor, rapid traverse motor, coolant pump motor, electrical control panel, work light, connecting cables and conductors, safety devices, etc. The electrical wiring and electrical panel are built as per the main motor power, supply voltage and frequency, upon a customer s order. All electrical motors are of three-phase and asynchronous type. The distributing transformer consists of a primary winding, a voltage, the frequency of which is fulfilled as per the customer s order, and two secondary windings for 24V AC. The local lighting is supplied with 24V AC according to the safety norms. The machine is supplied with the protocol of machine accuracy SHORTING AND LOAD PROTECTION MEASURES The main motor and that of the coolant pump are protected against short circuit through thermal protectors, located in the panel, and against overloading through an over-current protection system (thermal bi-metal relays) FT1, FT2, FR1; The rapid traverse motor is provided only with thermal protection. The transformer (ТС) is protected with fuses FU1 FU OTHER SAFETY MEASURES For its mechanical and electrical protection, the machine is equipped with the following micro-switches: Micro-switch for the electrical cabinet door SQ 1 Micro-switch for the shield of the universal chuck SQ 3 Micro-switch for the clutch SQ 4 Micro-switch for the quadrant box door SQ 5 Emergency stop-button (red mushroom) on the panel of the headstock SB 0 Emergency stop-button (red mushroom) on the panel of the apron SB 5 The electrical equipment and devices, connectors and all electrical elements of machine electrical equipment are protected from mechanical, atmosphere and chemical effects. Protection against an accidental machine setting in motion, with a spindle being not released ( switch SQ 4 ) BSeries_manual_rev docx Page 60 of 70

61 7.4. MAINTENANCE Warning: Access to the electrical cabinet is allowed only for a qualified electrical technician or a person, authorized by the owner, being instructed on high voltage safety procedures. The machine shall be checked or repaired only after the main switch has been disconnected from the electrical cabinet QS 0. Lockout-tagout procedures may need to be applied INSPECTIONS For the safe operation of the machine the following should be carried out: The zero-grounding (earthen) of the machine should be made in accordance with the local electrical safety regulations. In case of non-compliance with these requirements, immediate measure should be undertaken; The condition of the connections of all conductors and cables should be checked and they should be tightened, if necessary; The condition and functioning of the micro-switches of the electrical cabinet door (SQ 1 ), universal chuck shield (SQ 3 ), clutch (SQ 4 ), quadrant box door (SQ 5 ) and of the two emergency stop-buttons (red mushrooms), (SВ 0 ) and (SВ 5 ) should be checked BSeries_manual_rev docx Page 61 of 70

62 8. PROTOCOL OF MACHINE GEOMETRICAL ACCURACY Lathe OF NORMAL ACCURACY Diameter of rotation up to 800mm Terms of acceptance DIN 8606 Type: Receiver Machine No. Order No. Date: Received by: 8.1. PRELIMINARY EXAMINATIONS О1 О1 Object of examination Figure Examination means Examination conditions Machine setting а) in longwise direction b) in crosswise direction High precise level. Optical or similar method. Accessories corresponding to the type of guideways See O1 а) The slide in the middle position measured points locate uniformly along the bed at even distances а) put the level on the front (resp. on the rear) guideway. b) put the level on the bridge (guide) It can be also over the cross or longitudinal slide. Marginal Deviation а)0.01mm за L до 500mm. (convex) Local tolerance: 0.02mm за L до 1000mm convex) Local tolerance mm на 250mm If the working length is over 1000mm, the admissible deviation is then increased by 0.01mm for every next 1000mm. (convex) Local tolerance 0.015mm на 500mm b)0.04mm/m Change of tilt Measured а)...mm for L up to. mm...mm for L up to.. mmm b)... mm/m BSeries_manual_rev docx Page 62 of 70

63 8.2. GEOMETRICAL TESTS G1 G2 G3 G4 G5 Object of examination Rectitude of the slide movement in horizontal plane, defined from the axis of rotation and the top of the tool. Parallelism btw the slide and tailstock guides at: а)- horizontal plane b)-vertical plane а)- Shaft play of the spindle b)- Motion precision in the front (end) face plane. Circular movement of the spindle taper. Circular movement of the internal spindle taper. а)- by the nose b- at distance of half of max. rotative dia. Figure Examination means Examination conditions а) L up 1500 mm ind. Dial acc to DIN 879. Arbor or guide way of 300 up 500 mm length b) for all lathe lengths. String and microscope, or an optical method. Index dial acc. to DIN 879 Index dial acc. to DIN 879 (Auxiliary check facilities) Index dial acc. to DIN 879 Index dial acc. to DIN 879 Test arbor with Morse shank. а)-arbor between centers.ind. dial is over the slide. Nose touches the arbor in a horizontal plane. The slide is moved long-wisely resp. the arbor. b)-string fixed to the spindle box, passed over roller to the end body and stretched by a plumb bob. Microscope is on the slide. The string id straightened at the cross of microscope in c and d. The slide is moved along the string. Put ind. dial on the slide. Meas. nose touches the tailstock quill. The quill is in its working position. The slide with tailstock are moved along the bed. The ind. dial is located: а)- in spindle shaft b)- on spindle The spindle is rotating slowly. In case of bearing play apply force F, defined by. Locate ind. dial perp. To the envelope line of the taper. Rotate the spindle slowly. In case of bearing play apply force F, defined by the manufacturer. The arbor is inside the taper. The ind. dial touches the generating line of arbor. The spindle is rotating. Measure in a) then in b) Marginal а) and b) 0.015mm L to 500mm 0.02mm L above 500mm to 1000mm If the processing length is above 1000mm, the admissible deviation is increased by 0.005mm for each next 1000mm, without excessing 0.03mm а) and b) 0.03mm L up 1500mm Local tolerance 0.02mm to 500mm а) and b) 0.04mm L above 500mm Local tolerance 0.03mm to 500mm а) 0.01mm b) 0.02mm (including shaft play) 0.01mm а)0.01mm b)0.02mm for distance of 300mm Deviation Measured а)...mm b)...mm а)...mm b)...mm...mm...mm а)...mm b)...mm...mm а)...mm b)...mm G6 Parallelism btw the spindle shaft and the slide moving at a distance of half of max. rotative dia. а)- in horizontal plane b)- in vertical plane Index dial acc. to DIN 879 Test arbor with Morse shank. The arbor id inside the taper, fixed on pos. Standard deviation from circular movement. By meas. nose trace envelope line of the arbor. Move the slide at the meas. length. а) 0.15mm at 300mm in the tool direction b) 0.02mm at 300 mm in upward direction а)...mm b).....mm G7 G8 Parallelism btw the tailstock quill and the slide movement. а)- in horizontal plane b)- Parallelism btw tailstock taper and slide Index dial acc. to DIN 879 Index dial acc. to DIN 879 The procedure is the same as in G5. Ind. dial touches the hidden а) 0.015mm quill in: at 100 mm с. The quill is extracted by 100 in the tool direction mm and fixed again. b) 0.02mm The slide is moved till d) at 100 mm Measur. in c), then in d). in upward direction The arbor is inside the hidden and fixed tail stock quill. а) 0.03mm at 300mm in the tool direction а)...mm b)...mm а).....mm b)...mm BSeries_manual_rev docx Page 63 of 70

64 Object of examination movement. а)- in horizontal plane b)- in vertical plane Figure Examination means Examination conditions Test arbor with Morse shank. Place ind. dial in с), move the slide along the arbor. Deviation Marginal Measured b) 0.03mm at 300 mm in upward direction G9 Equidistance of both centers resp. to the base plane. Index dial acc. to DIN 879 Test arbor for clamping btw centers Tailstock and quill are tighten. With ind. dial trace generating line of the arbor. Meas. At both ends of arbor. 0.04mm (tailstock centre is higher)...mm G10 Parral. Btw the spindle shaft and the top slide movement. Index dial acc. to DIN 879 Test arbor with Morse shank.. Place top slide guides in par. With the spindle shaft in horizontal Plane. Lock the slide. Put the arbor inside the internal taper and guide it to the standard deviation from circular movement. The top slide with ind. dial, fixed to it, is moved along the arbor. 0.04mm at 300mm...mm G11 Perpendicularity of the spindle shaft towards the slide movement. G12 Осево биене на водещия винт G13 Pitch accuracy а)- achieved at lead screw drive b)-lead screw precision check Index dial acc. to DIN 879 Test pulley or quideway Index dial acc. to DIN 879 Стоманена съчма по DIN 5401 Index dial acc. to DIN 879 ans и образцов винт b)-precise meas. Device (use nut or nut segment) Ind. dial is fixed to the cross slide. Test pulley or quideway are fixed to the spindle. Move cross slide at...mm The ball, placed in the center hole, is traced by the ind. dial. The slide is driven by the leadscrew in the both directions. This test may be missed if the practical test P3 is fulfilled (work accuracy) а)-place test screw btw centers, trace it with ind.dial. b)-instead of а) may be applied meas. diagram of the leadscrew before assembling mm at 300mm directional error if 90º 0.015mm in each direction а) и b) 0.04mm at 300mm L up 2000mm meas. At any place. If the machine length is greater then 2000mm, then the admissible deviation is increased by 0.005mm for each next 1000mm, without exceeding one max. admissible deviation of 0.05mm at 300mm. Local tolerance 0.015mm at 60mm measured at any place...mm...mm а)...mm b)...mm...mm BSeries_manual_rev docx Page 64 of 70

65 8.3. PRACTICAL TESTS Inspected object P1 Work accuracy at plain turning а) circular b) cylindrical Figure Conditions of processing and means of measurements If no any prior agreement, the producer defines: type of the tool, material test workpiece (cast iron or steel), feeds, cutting depth and speed, etc. Check-up instructions а) two- or three measur. points. Max. difference in dia. is a deviation value. b) difference btw two turning dia. is a deviation value Admissible а) 0.01mm b) 0.04mm l= 300mm Deviations Measured а)...mm b)...mm l=...mm P2 Working accuracy at surfacing d da/8 da largest rotation diameter l=0.5 da The workpiece is clamped and machined. Micrometer or gauge with index dial to DIN879 Clamp test. Workpiece. On its head there are three circular planes, being machined by one run. Guideway of appr. Length, check plate (thickness gauge) Lay the quideway over the turning surface. Distance btw the quideway and the workpiece is set by means of check plates (gauge) mm d=300mm surface should be concave only...mm d=...mm Р3 Accuracy of thread pitch d 0.5 da l= da/8 Accuracy of thread pitch was controlled by G3. Practical test is fulfilled under spec. agreement. Clamp the workpiece btw. The centers and machine it by one run. Start thread cutting at any place of the leadscrew. Precise measure. device Test method depends on type of measur. Device. 0.04mm at 300 mm L up 2000 mm measured at any point. Local tolerance 0.015mm at 60mm measured at any point...mm...mm BSeries_manual_rev docx Page 65 of 70

66 9. INCLUDED ACCESSORIES 9.1. CARRIAGE STOP-LIMITER The carriage stop-limiter is designed to restrict the longitudinal apron lead travel. When the apron is moved towards the headstock, the screw (3) of the limiter touches the rest, located on the apron plate. The apron stops upon reaching the maximum tractive force by actuating the safety mechanism of the feed drive, located on the apron. The adjustment of the limiter is made at two stages its location at an appropriate place along the length of workpiece by using the bolt (5), and a fine type of adjustment though the bolt (3) and the counter-nut (4). Attention! The carriage stop-limiter should not be used for threads cutting. Figure 9-1 Carriage stop-limiter BSeries_manual_rev docx Page 66 of 70

67 9.2. TAPER The taper turning attachment is available as a standard option, which internal and external tapers can be machined to a length of 400mm and a maximum taper degree of 10. It is coupled directly to the saddle. The taper turning attachment is constructed and designed for high precision machining and easy handling. The adjustment of the taper turning attachment is made in the following way (Figure 9-2): By screwing the nut (5), the bolt (2) is tightened to the saddle (6) of the taper turning attachment; The housing (1), where the bolt (2) enters and is tightened through the nuts (3), should be tightened at a proper position along the lathe bedway on its rear saddle by three bolts (4) and a hub; Release the bolts (7) and (8); Set though the screw (9) the guide (10) at the desired angle, which can be read on the scale; Tighten the bolts (7) and (8); The taper section should conform to the following requirements: The taper section at the beginning of the taper should be not greater then 8mm, if the system clearance is not eliminated. The angle tolerances should be not greater than 15. Figure 9-3 Taper BSeries_manual_rev docx Page 67 of 70

68 9.3. FACEPLATES/CHUCKS Faceplates are designed for processing of materials of non-typical forms for a rotational surface machining (turning, boring). Machining of such materials is made through adjustment of the position of the jaws of the faceplate and by using an angle. Fixing of faceplate on the spindle is made in the way, described in item or Tightening of the workpiece at the faceplate by the jaws (Figure 9-6) is made by means of the jaw (5), screw (4) and key (10). Each jaw can be moved independently. Warning! The number of the revolutions (RPM), which is indicated on the faceplate plate, should not been exceeded. The number of the revolutions is defined depending on the weight, configuration, symmetry of the workpiece and centrifugal forces, which might result from the rotation. Fig. 9-6 Faceplates with jaws Fig. 9-7 Faceplates without jaws BSeries_manual_rev docx Page 68 of 70

69 9.4. STEADY REST AND FOLLOW REST The steady and follow rests are accessories to the lathe. They are used for additional support of a workpiece during its machining. The follow rest should be fixed tightly to the tool-head by means of bolts (12). Tightening of the workpieces is made by loosening the bolts (9), and the quills is moved by using the handles (2) and screws (6), till the caps rest at the workpiece. At this position, the quills can be locked by tightening the bolts (9). The steady rest is used for additional support, when workpieces of a long length and a small diameter are machined. Figure 9-9. Follow Rest BSeries_manual_rev docx Page 69 of 70

70 The steady rest, shown at Figure 9-10, should be tightened to the bedway parallels by using the clamp (16), bolt (15) and nut (13). On the rest as tightened, at a preliminary specified place along the bed length, the bolts (8) are loosened, and the quills are moved to their end outside position. The arc is released from the base by unscrewing the screw (11) by means of the handle, and it is moved backwards. After positioning of the workpiece, the arc should be closed and tightened to the base by using the screw (11). Supporting of workpieces is made by moving the quills (9) towards the workpiece, till the caps (10) reaches it. The quills can be locked by tightening the bolts (8). The steady rest is used for supporting of heavy-weight workpieces and such of large diameters. The steady rest can be equipped with roller tips, upon a customer s request. Remark: Supporting of workpieces by using steady s over the unfinished surfaces is prohibited! Figure Steady Rest BSeries_manual_rev docx Page 70 of 70