OPERATORS MANUAL
Contents
1. 2 a wea J gt E E 85 Knob a Fined Gover 1 s Hande a Screw mxo 2 s pa gt cearr Fr 29 Feeding Screw 19 1 THE HEADSTOCK The motor provides a direct drive to the Spindle via an internal tooth type belt Spindle speed is variable and is regulated by the Speed Control Knob 23 located on the main control panel The spindle is provided with an internal No 3 Morse taper to accommodate a centre for use with a face plate or turning clamp The 3 Jaw Self Centering Chuck 4 is mounted on the Spindle Flange 2 To remove the chuck simply remove the three securing nuts to the rear of the flange allowing it to be pulled free together with the three mounting studs Three external jaws are also supplied which extend the capacity of the chuck Their uses and method of assembly is described under Accessories The spindle has 6 holes drilled in its flange to accommodate a range of fixtures such as d Face Plate 4 Jaw chuck etc See Accessories 2 THE RUNNING GEAR The Running Gear is protected by a cover 22 which is removed by unscrewing the two securing hex screws The gear train shown in Fig 2 transmits drive to the lead screw The Lead Screw acts as a worm and by operating the Auto Feed Lever 15 which engages a nut with the lead screw worm drive is transmitted to the saddle and consequently the cutting tool thereby providing a power feed for screw cutting or general turning ope2. Keep work area well lit Do not use tools in the presence of flam mable gases or liquids Keep children away All children should be kept away from the work area Guard against electric shock Prevent body contact with grounded surfaces such as pipes radiators ranges and refrig erator enclosures Stay alert Never operate equipment if you are tired Do not operate the product if under the influence of alcohol or drugs Read warning labels on prescriptions to determine if your judgment or reflexes might be impaired 8 Do not wear loose clothing or jewelry as they can be caught in moving parts 9 Wear restrictive hair covering to contain long hair 10 Use eye and ear protection Always wear ANSI approved chemical splash goggles when working with chemicals ANSI approved impact safety goggles at other times ANSI approved dust mask or respirator when working around metal wood and chemical dusts and mists A full face shield if you are producing metal or wood filings NO oe 1 WIRING DIAGRAM 1 22 4 AC 220V 240V PARTS DIAGRAM 21 11 Keep proper footing and balance at all times 12 Do not reach over or across running machines 13 Always check that adjusting keys and wrenches are removed from the tool or machine work surface before plugging it in 14 Do not carry any tool with your finger on either the start button or trigger 15 When servicing use only identical replacement parts Be
3. be left unattended turn the F O R switch to the OFF position then disconnect from the mains supply CAUION ALWAYS turn the machine OFF at the Forward off Reverse switch BEFORE attempting to change any settings or make any adjustments This in cludes changing from High to Low range OPERATION A SIMPLE TURNING Before starting the machine as described above it is imperative that the setup for the type of work to be carried out is fully checked The following notes are guidelines as to how to set up the lathe in order to carry out a simple turn ing operation ALWAYS plan your work Have drawings or a plan on hand together with any measuring instruments you may require such as micrometers verniers calipers etc select a cutting tool that will produce the desired cut and mount it in the Tool Rest with as little over hang as possible securing it using three hex socket head screws in the manner shown in FIG 6 Ideally the overhang should be approx 10mm but not more than 15mm for a straight tool It is IMPORTANT to ensure that the tip of the cutting tool is on the centre line of the work or very slightly below it On no account should it be above the centre line Where necessary shims should be used beneath the tool in order to achieve the correct height or if the tip is too high the only recourse is to select another tool or grind down the tip To check to ensure the tip is at the correct height position the to
4. so that short tapers or bevels may be cut This is described in greater detail under Bevel Cutting The cross slide and compound slide feeds are provided with a scale These are used to move the tool by precise amounts one division being equivalent to 0 001 0 025mm As the feed handle is furned so does the scale The scale on the cross slide feed may also be held stationary whilst the handle is turned allowing the scale to be zeroed The manner in which this is put to use is discussed in greater detail under Operation Fig 3 The tool post carries 8 hex socket head screws Which are used to secure a cutting tool in any de sired position Four may be mounted for conve nience and to speed up your operation Two are shown mounted The tool post is rotated by slackening the lever A on its top sufficient for the post to be lifted slightly and then turned to the desired position ALWAYS ensure the post and hence the tool is se cured by screwing down the lever firmly before attempting to cut 5 THE MOTOR It is not recommended that you dis assemble the motor Brushes may be replaced as described under Maintenance For all other servicing and repairs please contact your dealer UNPACKING amp PREPARING FOR USE On receipt carefully unpack the lathe inspect to ensure that no damage was suffered in transit and all parts are accounted for Should any damage be apparent or parts are missing please contact you
5. E G LOW VOLTAGE DIRECTIVE 73 23 EEC AMENDED BY 93 68 EEC DECLARATION OF CONFORMITY We hereby certify that OSAKI MML300 Mini Lathe Complies with all the relevant provisions of the POWE Fe TOO LS EC Directives 73 23 EEC amp 93 68 EEC Harmonised Standards Applied EN61029 1 2000 EN12840 2001 EN55014 1 2000 A1 2001 A2 2002 EN55014 2 1997 A1 2001 EN61000 3 2 2000 ENG1000 33 19854M1200 Mini Metal Working Lathe Official Agent KENNEDY TOOLS Wigston Works Leicester England ISO 9002 REGISTERED COMPANY sarea ao Boka Date ist September 2006 Name Martin Cooke Position Director The Kennedy Group Ltd QUALITY GUARANTEE amp WARRANTY OSAKI POWER TOOLS carry one years manufacturers warranty OSAKI POWER TOOLS are designed amp produced to the highest standards amp specifications OSAKI POWER TOOLS are fully guaranteed against faulty materials amp workmanship Should they be found to be defective they will either be repaired or replaced free of charge fair wear and tear and or misuse excepted Please retain supplier invoice as proof of purchase These machines are designed for D I Y and hobby use They are not covered by an Industrial Warranty Industrial use will invalidate this guarantee AVAILABLE FROM YOUR DISTRIBUTOR ORDER CODE MML300 05A 271 5000K OPERATORS MANUAL O The Kennedy Group Ltd 08 06 WIRING DIAGRAM 2 CONTENTS Specifications Important Safety Instruction Feature and
6. Gear D as the Driven gear When a Simple gear train is configured as illustrated in Fig At the gear at B acts as an Idler and its size is therefore irrelevant any convenlent gear will suffice to connect A and D This is denoted by a blank space in the column in the gear chart 13 The setup is now complete to begin your cutting operation but before starting check the position of a Auto feed lever Ensure it is in the UP position for manual feed b Forward Neutral Reverse leadscrew lever If Auto feed is not required set to Neutral c HIGH LOW lever Select required speed range Switch the machine ON as described under Starting Procedure and slowly feed the cutting tool into the work using the Manual Feed Handle Proceed until you reach the previously marked line on the work then retract the tool one or two complete turns on the Cross Slide feed handle Wind the saddle back to the begining then wind the tool the same number of turns iN plus the depth of desired cut and proceed to cut once more NOTE This describes the procedure for general rough cutting For other types of cuts finishing cutting shoulders etc you should consult a suitable handbook B SIMPLE TURNING WITH POWER FEED The same basic setup is used as described above except that before starting the Leadscrew F N R Lever 25 is set to the Forward position and the Auto Feed Lever 13 is operated in order to drive the saddle As mentioned pre
7. Legend i or 1 The Headstock 2 The Running Gear i 3 The Tailstock 4 The Saddle 5 The Motor Unpacking and Preparing For Use Installation Starting Procedure Operation Change Gear for Screw Cutting Maintenance Setting and Adjustment Accessories Parts List and Parts Diagram Wiring Diagram SPECIFICATIONS Max swing over bed 180mm Max length of workpiece 200mm model 200 300mm model 300 Spindle taper Morse No 3 Tailstock taper Morse No 2 Spindle bore 20 mm Cross slide travel 65 mm Compound slide travel 55 mm effective Spindle speed variable speed 100 2500 rpm effective Longitudinal feeds 0 1 0 2 mm Screw threads Imperial 12 52 TPI in 18 steps or Metric i 0 4 2 0 mm in 10 steps The item marked has different choice see the label in front of the machine or ask information to your dealer Important Safety Instructions READ ALL INSTRUCTIONS AND WARNINGS BEFORE USING THIS TOOL Operator COMMON SENSE AND CAUTION ARE FACTORS WHICH CANNOT BE BUILT INTO ANY PRODUCT THESE FACTORS MUST BE SUPPLIED BY THE OPERATOR PLEASE REMEMBER 1 When using electric tools machines or equipment basic safety precautions should always be followed to reduce the risk of fire electric shock and personal injury 2 Keep work area clean Cluttered areas invite injuries 3 Consider work area conditions Do not use machines or power tools in damp wet or poorly lit locations Do not expose equipment to rain
8. adjuster or jib screws mounted along its length The jib screws are to be found on the right hand side of the slide directly beneath the compound slide handie In time wear will occur on the mating surfaces resulting in a sloppiness of action To adjust the jib strip to account for wear and ensure the slide moves evenly and smoothly pro ceed as fOllows 1 Slacken off all lock nuts and screw inthe jib screws iA evenly i e use the same torque for each screw acces The slide should be held firmly Test by trying to Gib Strip Screws turn the handle but do not force it 2 Screw out each jib screw by one quarter of a turn ONLY and nip up the lock nuts s ISSS 3 Test again by turning the handle The movement should be even and smooth along its complete length 4 If the movement is too slack screw all adjusters in by one eighth of a turn and re try Similarly if the movement is too stiff screw out the adjusters by one eighth of a turn until the correct adjustment is attained 5 Tighten all lock nuts taking care to ensure you do not move the jib screws whilst doing so 6 When completed retract the slide fully and apply oil to all mating surfaces and the feed screw thread then wind the slide back to its normal position B CROSS SLIDE FEED HANDLE The cross slide feed should run smoothly and the scale must rotate with the handle If any stiffness occurs it is probably the result of swarf lodging betw
9. cautions when moving the lathe considering its weight Assistance will be required Ensure the location is adequately lit and that you will not be working in your own shadow We strongly recommend that the machine is bolted firmly to a strong workbench using the tapped holes used to secure the feet to the lathe This is to provide added stability and consequently additional safety 475mm To do this remove the four M screws which se cure the rubber feet and chip tray to the ma chine if already fitted and discard the feet Drili four M6 clearance holes in a worktop at the dimensions shown in the diagram opposite and with appropriate length M6 boits or screws with flat washers not supplied proceed to secure the lathe to the worktop ensuring the chip tray is in place For model 200 For model 300 72mm Alternatively if you do not wish for a permanent installation you may secure the lathe to a 5 8 thick plywood board with a minimum recommended dimension of 800x300mm the mounting holes being centralised on the board When the lathe is in use the board should be clamped to work bench using with G clamps STARTING PROCEDURE A DURING INSTALLATION INITIAL START ref Fig 5 Taking all precautions previously stated set the High Low range lever item 26 to LOW Ensuring the cross slide is well away from the Fig 5 chuck and the automatic feed lever is in its dis engaged position i e lever is UP insert the e
10. cut is vitally important and may be calculated or obtained from an appropri ate reference manual 3 Take all necessary precautions previously stated and start the machine with the automatic feed lever in its disengaged position UP 4 aa the auto feed lever sharply turn the FORWARD OFF REVERSE F O R switch C to FOR NO As the tool approaches the end of the desired thread turn the switch C to OFF Do not disengage the auto feed lever 11 5 Retract the tool using the cross slide feed handle noting the exact position on the scale and the exact number of turns Turn the switch C to REVERSE the saddle winds back to the beginning and turn switch C to OFF Reset the tool by winding IN the cross slide the exact number of turns previously wound OUT and then continue to wind IN the to the desired depth of cut 6 Repeat the step 4 5 Proceed in this manner until the thread is completed CHANGING GEARS FOR SCREWCUTTING The leadscrew is driven via a gear train by a gear on the spindle The gear ratio will therefore determine the rotational speed of the leadscrew with relation to the spindle i e one turn of the spindle will turn the leadscrew an amount determined by the gear ratio By setting the gears to a known ratio we can therefore produce threads to a known size and as the leadscrew supplied produces Imperial threads the known values will be in Threads Per Inch TPI or if the leadscrew supplied produces Me
11. d will result in a safety hazard and void the warranty DO NOT MODIFY THE PLUG IN ANY WAY IF YOU HAVE ANY DOUBT CALL A QUALI FIED ELECTRICIAN FEATURES 23 24 25 Rear view of headstock Headstock Spindle Flange Chuck Guard Accessory 3 Jaw Chuck Tool Post Cross Slide Conlpound Slide Tailstock Centre Tailstock 10 Tailstock Securing Nut 11 Bed 12 R H Leadscrew Bearing 13 Compound Slide Feed Handle 14 Thread Dial Indicator Accessory OONOARWN Fig 1 9 6 7 8 9 17 1 19 13 12 LEGEND 15 16 17 18 12 20 2 ZA 23 24 29 26 49 Automatic Feed Lever Cross Slide Feed Handle Apron Manual Saddle Feed Handle Leadscrew Motor Brush Cap Thread Dial Indioater Table Accessory Running Gear Cover Variable Speed Control Knob Forward Off Reverse Switch Emergency Stop Switch High Low Speed Range Lever Leadscrew Fwd Neutral Rvrse Lever No Description Q ty No Descriptin ty 140 Bracket L 90 NutMS 4 140 Bracket Cd 91 Screw mexi2 6 141 SrewM4X10 PT 2 93 Saddle 143 Centre 1 93 1 143 Centre Cd oOo 96 SwvDik CT 1 146 Hnde_ NT 97 Screw m8x20 6e 148 Puy PP 7 98 Nim 6 150 mior i 99 Screw Mm4x16 3 151 cvr Ti Cross Slide Screw M4 X 8 2 154 FNRLabl CT 1 Screw M4 X 14 Compound Rest A Screw M6 X 25 8 160 Geawei J Tool Rest 113 Stud M10x65 1 163 GeawhesTt 7 C
12. de for easier reassembly un screw the nut securing the shaft carrying B and C and the nut securing the adjuster A 3 Remove the gears taking care to retain the small keys on each shaft and replace with those neces sary to produce your screw thread They may be mounted either way round The number of teeth on each gear is clearly marked Replace the securing screws ensuring the flat washer bears up against the gear hub in each case i Adjuster A NOTE If a compound gear train is required as shown in Fig B ensure the spacer which is keyed to the shaft carrying gear D is located on the shaft BEFORE the gear in order to align gear D with gear C 4 Proceed to move the shaft carrying B and C and the adjuster A so that all gears mesh cor rectly then tighten the adjuster securing nuts This may take one or two attempts but make sure there is as little backlash as possible without being overtight Turn the spindle by hand to test for backlash Replace the cover and secure with the two hex socket head bolts MAINTENANCE For maximum performance it is essential that the lathe is properly maintained BEFORE USE Always inspect before use Any damage should be repaired and maladjustments rectified Dam age to machined surfaces should be repaired with an oil stone Test by hand to ensure smooth operation of all parts before use Inject a few drops of oil to the oilways at both leadscrew bearings each end bracket and once
13. dstock under power the same as cutting using auto feed except the rate of feed is greater as determined by the gear configuration The cutting tool therefore is moving ever closer to the rotating chuck Great care and concentration must be exercised to ensure that the two do not meet when the machine is operating as the possible damage caused could be disastrous The lathe is supplied with a leadscrew that will produce Imperial Threads in a range from 12 to 52 threads per inch or metric threads in a range from 0 4 2 0mm pitch it is important to remember that the type of thread you need to cut i e UNF BA BSP BSW etc will be totally dependant upon the cutting tool profile as profiles differ from thread to thread For detailed information regarding screwcutting techniques cutting tools etc you should con sult a suitable handbook or obtain advice from a qualified person The general procedure for screwcutting is as follows Try to get as much distance from the chuck to the end of the proposed screw thread as possible and if your design allows cut a run off into the workpiece which is of a smaller diam eter than the root diameter of the proposed screw thread Note that for long threads it may be necessary to use steady s see Accessories Install the appropriate gears for the thread required and correctly mount the cutting tool set your required depth of cut and position the tool ready to begin cutting Note Depth of
14. e passes the mark on the body of the dial indicator engage the auto lever sharply and thread cutting will commence 2 As the tool approaches the end of the de 15 sired thread DISENGAGE THE AUTO FEED LE VER Do not switch the machine OFF Lo 3 Retract the tool using the cross slide feed 1 handle noting the exact position on the 1357 scale and the exact number of turns Pace Wind the saddle back to the begining and 1 5 reset the tool by winding IN the cross slide IB ine exact number of turns previously wound LS OUT and then continue to wind IN to the de sired depth of cut 1 3 5 7 1 8 4 With the machine still running observe the 1 3 5 7 dial indicator and gs the same numbered line passses the mark on the body engage 1 9 the auto feed lever once again Proceed in l 8 this manner until the thread is completed 1 3 5 7 Engaging the auto feed lever as your predeter re mined line on the dial passes the mark on 1 3 5 7 the body ensures the half nuts of the auto IMPERIAL METRIC feed mechanism engage in the same ie thread on the leadscrew each time thereby 1 0 5mm T 0 6mm T 1 MMA ensuring the cutting tool is in the same place j ppl ee for each pass which in turn produces a per 3 0 7mm 1 75mmT 1 4 5 fect thread 4 0 4mmy1 1 3 5 7 5 0 8mm1 1 5 External Jaws 3 Jaw Chuck To change the jaws insert the chuck key and open the jaws to their fullest extent It will then be possible to remove each jaw in turn Replace them with t
15. een the mating surfaces Undo the securing hex socket head screw securing the handle Remove the handle and pull off the collar with the scale taking great care to retain the small spring plate which sits in a groove beneath the collar Clean the assembly and reassemble in reverse order It will be necessary to hold the spring plate in place with a small screwdriver or similar tool and pushing down on it to allow the collar to be correctly located on to the shaft 15 B STARTING UNDER NORMAL CONDITIONS ref Fig 5 1 Take all necessary precautions previously stated and ensure the workpiece can rotate fully without obstruction 2 Set the Speed Range control lever to HIGH or LOW as required 3 Set the Forward Off Reverse F O R switch C on the main control panel to the FORWARD position 4 Engage or ensure the Auto Feed lever is dis engaged depending upon whether or not auto matic feed is required IMPORTANT This should ALWAYS be a deliberate conscious action NOTE If Auto feed is required the Leadscrew Foward Neutral Reverse Lever should be set to FORWARD If Auto feed is not required the lever may be set to Neutral To do this grasp the knurled handle and pull out against spring pressure Holding the handle in this position move the lever until the point on its end locates in the middle pit mark in the casing 5 Proceed to start the machine as described in Section A above 6 If the machine is finished with or is to
16. fectly clean corners then you need to use an appropri ately shaped tool 5 Retract the tool one or two complete turns on the cross slide feed then wind the saddle so that the tool is at the start point once again Advance the tool the same number of turns plus the depth of cut and when ready push down the auto feed lever and procede to take another Cut 10 CG BEVEL CUTTING Bevel cutting invoives the use of the Compound slide which is mounted on the cross slide and set at right angles to it for all normal cutting operations This is indi cated by the zero mark on the scale B Fig 8 lining up with the mark etched on the body of the cross slide To set the compound slide so that the cutting tool will cut a bevel first retract the slide until the two hex socket head screws A are revealed as shown in Fig 9 slacken the screws sufficient to allow the compound slide to be turned to the desired angle as indicated on the scale and secure the slide in this position by retighten ing the hex socket head screws The taper or bevel is cut by setting the cross slide ap propriately then using the compound slide feed handle to advance the cutting tool in the direction of the arrow as shown in Fig 9 D SCREWCUTTING This operation requires a degree of skill and accuracy and should not be attempted unless you are completely familiar with all aspects of the lathe Essentially the saddle will move towards the hea
17. fore Operation 1 Be sure the switch is OFF when not in use and before plugging in 2 Do not attempt to use inappropriate attachments in an attempt to exceed the tool s capacity Approved accessories are available from the dealer or machine maker 3 Check for damaged Parts Before using any tool any part that appears damaged should be carefully checked to determine that it will operate properly and perform its intended function 4 Check for alignment and binding ofall moving parts broken parts or mounting fixtures and any other condition that may affect proper operation Any part that is damaged should be prop erly repaired or replaced by a qualified technician 5 Do not use the tool if any switch does not turn off and on properly Operation 1 Never force the tool or attachment to do the work of a larger industrial tool lt is designed to do the job better and more safely at the rate for which it was intended 2 Do not carry the tool by its power cord 3 Always unplug the cord by the plug Never yank the cord out of the wall 4 Always turn off the machine before unplugging IF THERE IS ANY QUESTION ABOUT A CONDITION BEING SAFE OR UNSAFE DO NOT OPERATE THE TOOL Grounding Instructions This machine has a three prong plug the third round prong is the ground Plug this cord only into a three prong receptacle Do not attempt to defeat the protection the ground wire provides by cutting off the round prong Cutting off the groun
18. he external jaws noting the fol Fig 14 lowing a The thread segments of the jaws are progressively stepped as shown in fig 14 They are also numbered 1 to 3 This is to take into account the lead of the screwthread within the chuck It is therefore neces sary to assembie the jaws in the correct order Place them as shown in the fig 14 and assemble in the same order clockwise in the slots in the chuck turning the chuck key as you insert them Close the jaws fully and check to ensure they all meet at the centre If a jaw is out open the jaws fully and retain pressure on the jaw in quesfion whist turning the chuck key until it snaps down into position Re check to ensure all jaws meet at the centre Fixed and Moving Steadies Fig 15 illustrates the Fixed Steady A and Movong Steady B assembled to the lathe used to support a long workpiece Fig 15 With assistance considering the weight of the machine raise it on to a good solid surface or workbench Proceed to remove all traces of preservative with paraffin or good quality solvent and lightly oil all machined surfaces You will notice that for transit purposes the cross slide feed handle has been mounted in reverse Remove it by Eine hex socket head screw securing it and mount it the correct way round Then turn all feed handles to ensure they are free and move evenly and smoothly Attach the plastic handles to the rims of the manual feed and tailstock feed hand
19. ide and compound slide adjustments are correctly carried out and that there is no sloppiness of action Any maiadjustments will have a serious effect on the quality of your work as they will all be transferred to the tool tip It is vital that there is as little movement of the tool as possible ACCESSORIES A range of accessories is available from your versatilihy of your machine These are gs follows Fig 13 1 Independant 4 Jaw Chuck 80mm dia 2 Face Plate 160mm dia 3 Moving Steady 4 Fixed Steady 5 Tailstock Drilling Chuck with a 13 mm capacity b Headstock Centre MT3 7 Revolving Centre Tailstock MT2 8 6 Piece Cutting Tool Set Comprising tools for 60 thread cutting parting grooving facing and general turning work Hex wrench not shown 9 Thread Dial indicator not shown Imperial or Metric 16 MOTOR BRUSHES The Motor brushes may be changed by un screwing the caps visible at the front and rear of the machine beneath the Headstock as shown in Fig 11 SETTINGS AND ADJUSTMENTS Occasionally it may be necessary to readjust various components in order to maintain optimum performance The adjustments that may be performed are as follows A CROSS SLIDE ADJUSTMENTS The cross slide is mounted on a dovetail slide as shown in fig 12 Between the sloping surfaces on one side of the dovetail a jib strip is inserted which may be tightened against the dovetail under the influence of three
20. lec tric plug into its socket select FORWARD using the Forward Off Reverse F O R switch C on the main control panel then release the Emergency Stop switch by push ing down on the red knob slightly and pushing it in towards the headstock as indicated by the H D Ga L RPM arrow on the top of the red knob B gt switch on the machine by GENTLY turning the Variable Speed control knob A clockwise A click wiil be heard os power is turned on but the spindle will not rotate until the knob is turned clockwise a little further Speed will increase progressively the further the knob is turned Run for a total of 5 minutes during which time gradually increase spindle speed to its maximum Run for at at least 2 minutes at this soeed before stopping the machine and disconnecting from the mains supply Check that all components are still secure and working freely and correctly Check also to ensure the mountings are secure Repeat the procedure at the HIGH range setting should any adjustments be necessary refer to the appropriate section under Settings and Adiustments CAUTION NEVER attempt to change from HIGH to LOW range with the machine running C COMPOUND SLIDE ADJUSTMENiS Compound slide adjustments are made in the same way as those for the cross slide The jib screws are to be found on the left hand side of the slide i e facing the front of the lathe NOTE It is important that the cross sl
21. ol so that the tip is almost fouching the point of the tailstock centre They should coincide If necessary make adjustments using shims grind down the cutting tool tip or select another tool When satisfied mount the work either in the chuck or on a faceplate and if necessary use the tailstock centre for additional support If the work cannot be adequately secured by the chuck or if it is a long piece or of small diameter Additionally Steadies may be used which are de scribed in greater detail under Accessories If the Tailstock is not to be used you may remove it completely by slackening off ths securing nut at its base and sliding it free of the bed Mark the surface of the work at the point where the cut is to end i e the shoulder using a scriber or similar means and move the saddle so that the cutting tool is directly opposite the mark then wind in the cross slide so that the tool touches the surface of the work Whilst carrying out these manouvres rotate the chuck by hand to ensure that nothing will come into contact with it when turning takes place i e there is adequate clearance between the saddle cross slide tool post or cutting tool and the chuck it may be necessary to adjust the position of the compound slide or reposition the work in the chuck to guarantee that there is adequate clearance Fig 7 When satisfied retract the cutting tool and wind the saddle away from the headstock then wind the Cutting tool u
22. ortwice during the day if used continuously It will be necessary to remove the gear train cover in order to oil the left hand bearing Inject a few drops also to the compound slide oilway located on tne slides top surface between the two hex socket head screws AFTER USE Remove all swarf from the machine and thoroughly clean all surfaces If coolant has been used ensure it has completely drained from the tray Components should be dry and all mochined surfaces should be lightly oiled Always remove cutting tools and store in a safe place 14 GEAR CHART FOR CUTTING IMPERIAL THREADS Threads Examples Per Inch 1 Ref Fig A To cut 12 TPI use 40T in position A 30T in position D and any convenient gear in position B to connect A and D 2 Ref Fig B To cut 13 TPI use 40T in position A 65T in position B 60T in position C 30T in position D GEAR CHART FOR CUTTING METRIC THREADS Examples 1 Ref Fig A to cut O 5mm T Use 20T in position A 50T in position B 60T in position D and any convenient gear in position C 2 Ref Fig B to cut O 4mm T Use 20T in position A 50T in position B 40T in position C 60T in position D n ooooo 4 5 6 3 8 0 a Re 0 In order to change the gears ensure the machine is switched OFF and disconnected from the mains supply Remove the gear train cover which is secured with two hex socket head screws Gear A may be considered as the Driver and
23. p to the work somewhere along the length to be cut whilst rotating the work by hand using the chuck Continue to advance the cutting tool slowly until it just touches the surface Record this position by zeroing the scale on the cross slide i e turn the moveable scale until the Zero marks coincide see diagram opposite Once zeroed retract the cross slide one complete turn then move the saddle until the tool is a short distance from the right hand edge of the Work Wind in the cross slide again one full turn until the zero marks again coincide IMPORTANT If you go past the zero marks back off again at least one half of a turn then slowly bring the marks back together Whenever you use the scale as an indicator to advance the cross slide or Compound slide ALWAYS use this procedure to align the marks This is to take into account backlash and other clearances in the gearing and slides etc Continue to turn the handle an amount equivalent to your desired depth of cut NOTE We recommend that for rough cutting you do not exceed 0 01 0 0 25mm as your depth of cut The positions of the shafts carrying gears A and D are fixed therefore all adjustments are carried out on the shaft carrying gears B and C and the Adjuster A shown in fig 10 1 Unscrew the hex socket head screws securing gears A and D followed by the screw securing gears B and C NO To allow the gears B and C to disengage com pletely and to provi
24. r dealer immediately The following loose items are to be found in the packing case 1 4 x Rubber Feet 2 4 x M6 Pan Head Scews 4x Hex Keys X Chuck Key x Plastic Oil Container 1 X Spare Fuse glass type 2 x Plastic Handles w Nuts and Bolts No 2 Morse Taper Centre for Tailstock 9 3 x External Jaws for 3 Jaw Chuck 10 2 x Double Open Ended Spanners 8x10mm and 14x17mm Imperial Z 30 35 40 40 45 50 55 57 60 65 11 1 x Gear Set Metric 2 30 35 40 40 50 60 denotes not illustrated CON O OO HR W How to use a Thread Dial indicator Mounted on the Apron adjacent to the Auto Feed Fig 15 Lever is the Thread Dial Indicator shown in fig 15 This is permanently connected to the leadscrew and as the leadscrew turns the dial spins Eight radial at marks are etched on the dial and these are used to Baan mmm determine the exact position of the leadscrew thread in relation to the saddle i t dakaka bad hi hi ONES The numbers in the SCALE column refer to the num bers on the radial lines on the Indicator Dial Therefore if a 20TPI thread is to be cut for example the marks 1 3 5 or 7 may be used You should now procede as follows Observe the spinning Dial In particular con centrate on one of the numbered marks etched on the dial which corresponds to the scale number given in the Indicator Table IN our example this could be 1 3 5 or 7 As your line lin
25. rations The rotational speed of the lead screw and hence the rate of feed of the cutting tool is determined by the gear configura tion this is explained in greater detail under Screwcutting The drive to the leadscrew may be disconnected by operating the lever 27 and the same lever is used to drive the leadscrew in a forward or reverse direction These actions are described in detail un der Screwcutting 3 THE TAILSTOCK The Tailstock 9 may be moved along the bed to any desired position and is secured in position by a single nut 10 at its base The Tailstock Spindle carries an internal No 2 Morse taper for use with the Centre 8 provided A Revolving Centre and Drill Chuck are also available from your dealer see Accessories 4 THE SADDLE The Saddle carries the Cross Slide 6 on to which is mounted the Compound Slide 7 with Tool Post 5 allowing intricate and delicate operations to be performed It may be driven by the Leadscrew via a Drive Nut to provide automatic feed when the Auto Feed lever 15 mounted on the Apron 17 is operated The position of the tool is effected by turning the cross slide feed handle 16 which moves it across the lathe and the saddle or manual feed handle 18 which moves it longitudinally Additionally the compound slide feed handle 13 may be used to move the tool by small amounts at right angles to the cross slide or the slide may be set at an angle to the cross slide
26. ross Feed Screw Gearwheel 60T Screw M4 X 12 Cno nume 2 167 s JawChnuokky 3 Model Label 122 Swithlabel 1 170 ScewMSX5 J 17 125 RubberFoot 4 1733 ScewM5X10 4a 126 Chip Tray 1 174 Protector 1 126 Chip Tray CT 1 17 4 Protector 7 128 Key M3x16 1 176 num _ lt f 2 131 Bracket 1 178 Emergency StopSwith 17 132 PlasticPug 1 179 Fue_ _ 7 134 Rak 1 181 Fonwardof ReverseSwitch 136 Washer M10 1 183 Electric Filter 1 136 pt 183 ka oa 137 Screw M5Xx16 o o o ooi PT Tailstock Casting 2 AK Pe CE 139 TailstockScrew o doi PI Note No 157 167 Not Shown in Parts Diagram PARTS LIST me Description orty No Description aty r feawy OC joan ooo a 2 Chuck O o a Paay 6X8 3 E A Mount e num F5 50 Gearwneel 20T e Key maxs 2 52 Screw MX 8__ Screw msi e s ov Screw M5 X45 a2 fse ooo o e s Screw MEX Sd Spacer Gearwheel 807 Spur Gear 457 eo shat SS Suppor Plate Set Screw M5 XE 19 fseasaos lt 2 o mmm o 20 Compression Spring 3 a sa SY a fseswew mxs 3 685 pa lt n 22 Retaining Ring ma 2 66 sae 24 Hit Gear 121 00T_ 1 68 Dial indicator Boay 1 25 Parallel Key maxas 1 69 Set Screw Max 10 3 ae Washer Shaft 36_ Handle Mount 1 80 Sha oooO Feeding Gear 11 647 38 indicar O 1 2 Feeding Gear ar o Screw M6 X10 40 fsuponscew
27. tric threads the known values will be in mm pitch As previously mentioned the actual thread produced will be totally dependant upon the profile of the cutting tool It is not within the scope of this manual to provide detailed information regard ing types of cutting tool cutting soeeds and working with various types of material etc and it is strongly advised that you consult appropriate handbooks or seek advice from a qualified person The chart below shows the thread sizes that may be cut using the gear configuration shown in the corresponding columns NOTE The factory setup for the lathe provides for normal turning using the power or auto feed and the gear configuration is as follows Gear A 20T Gear B 80T Gear C 20T Gear D 80T 12
28. viously the rotational speed of the leadscrew and hence the rate of feed of the tool is dependant upon the gear configuration of the gear train The feed rate for normal furning is considerably iess than that used for screw cutting The lathe is factory configured for normal turning however if you have been screw cutting always remember to reset the gear configuration to that for normal turning Please refer to the chart on later page which shows the gear cofiguration and the explanation of how to change the gears on the same page 1 Taking all precautions previously mentioned position the cutting tool a short distance to the right of the workpiece with the appropriate depth of cut set on the cross slide 2 Ensure the leadscrew F N R lever is set to Forward and select Forward on the Forward Off Reverse switch on the main control panel Switch on the machine 3 Turn the knob to achieve your desired spindle speed with your right hand push down on the auto feed lever until the nut becomes firmly engaged with the leadscrew IMPORTANT Your left hand should always be free in order to hit the emergency stop should it become necessary 4 Carefully observe the movement of the tool and as it approaches the mark on the surface denoting the end of cut pull the Auto Lever UP sharply and ensure it stays UP If a degree of accuracy is required it is recomended that you finish the cut by hand NOTE If you require a shoulder with per
29. wheels respec M PPI ihe nuts are tight and the handles spin freely about the bolts witnout excessive end play saddle cross slide and compound slide adjustments are all factory set to ensure smooth move ment in both directions If however the adjustments have been upset during transit indicated by stiff or erratic movenlent refer to Settings and Adjustments for the methods of adjustment All hex keys and spanners necessary to carry out various adjustments are supplied together with a ek key for the 3 Jaw chuck and a spare fuse The fuse holder is located on the main control panel The four rubber feet are attached to the underside of the bed using ths four M pan head screws in the tapped holes provided These screws are also used to secure the chip tray We sjene recommend however that to provide maximum stability and additional safety you se cure the lathe to a firm foundation as described under Mounting the lathe The three external jaws for the 3 Jaw self centering chuck extend the capacity of the chuck and are discussed in greater detail under Accessories INSTALLATION CAUTION DO NOT ATTEMPT TO USE THE MACHINE UNTIL INSTALLATION IS COMPLETED AND ALL PRELIMINARY CHECKS HAVE BEEN MADE IN ACCORDANCE WITH THIS MANUAL MOUNTING THE LATHE The lathe should be mounted on a strong heavy workbench of suffcient height so that you do not need to bend your back to perform normal operations Take the necessary pre
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