Optimum 3427210 Operating Manual Download Page 2

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Version 1.1.6 - 2021-9-17

Translation of original instruction

TU3008G

3008G

_GB

IVZ.

Table of contents

Safety

1.1

Rating plate.................................................................................................................................................... 6

1.2

Safety instructions (warning notes)................................................................................................................ 7
1.2.1

Classification of hazards .................................................................................................................. 7

1.2.2

Pictograms ....................................................................................................................................... 7

1.3

Intended use .................................................................................................................................................. 8

1.4

Reasonably foreseeable misuses.................................................................................................................. 9
1.4.1

Avoiding misuse ............................................................................................................................... 9

1.5

Potential dangers that can be caused by the lathe........................................................................................ 9

1.6

Qualification ................................................................................................................................................. 10
1.6.1

Target group private users ............................................................................................................. 10

1.6.2

Obligations of the User................................................................................................................... 10

1.6.3

Additional requirements regarding the qualification ....................................................................... 10

1.7

User positions .............................................................................................................................................. 10

1.8

Safety measures during operation............................................................................................................... 11

1.9

Safety devices ............................................................................................................................................. 11
1.9.1

Emergency-stop switch .................................................................................................................. 12

1.9.2

Protective cover of the headstock .................................................................................................. 12

1.9.3

Lathe chuck protection with position switch ................................................................................... 13

1.9.4

Protective cover lead screw and feed rod ...................................................................................... 13

1.10

Safety check ................................................................................................................................................ 13

1.11

Personal protective equipment .................................................................................................................... 14

1.12

1.13

Electronics ................................................................................................................................................... 15

Technical specification

2.1

Electrical connection.................................................................................................................................... 16

2.2

Drive motor power ....................................................................................................................................... 16

2.3

Work areas .................................................................................................................................................. 16

2.4

Headstock.................................................................................................................................................... 16

2.5

Feeds and pitches ....................................................................................................................................... 16

2.6

Slides ........................................................................................................................................................... 17

2.7

Tailstock....................................................................................................................................................... 17

2.8

Machine dimensions .................................................................................................................................... 17

2.9

Work area .................................................................................................................................................... 17

2.10

Environmental conditions............................................................................................................................. 17

2.11

Operating material ....................................................................................................................................... 17

2.12

Emissions .................................................................................................................................................... 17

Delivery, interdepartmental transport and unpacking

3.1

Notes on transport, installation and unpacking............................................................................................ 18
3.1.1

General risks during internal transport ........................................................................................... 18

3.2

Delivery........................................................................................................................................................ 19
3.2.1

Load suspension point ................................................................................................................... 19

3.2.2

Lifting with lifting equipment ........................................................................................................... 20

3.2.3

Lifting with a forklift......................................................................................................................... 20

3.3

Machine Center of Gravity ........................................................................................................................... 21
3.3.1

without a machine base ................................................................................................................. 21

3.3.2

with an optional machine base....................................................................................................... 22

3.4

Installation conditions .................................................................................................................................. 22

3.5

Cleaning the machine .................................................................................................................................. 23
3.5.1

Lubrication...................................................................................................................................... 23

3.6

First commissioning ..................................................................................................................................... 23

3.7

Electrical connection.................................................................................................................................... 24

3.8

Warming up the machine............................................................................................................................. 24

Operation

4.1

Control and indicating elements .................................................................................................................. 25

Summary of Contents for 3427210

Page 1: ...GB Part no 3427210 Operating Manual Version 1 1 6 Lathe L691 ...

Page 2: ...y during operation 14 1 12 1 Disconnecting and securing the lathe 15 1 12 2 Using lifting equipment 15 1 12 3 Mechanical maintenance work 15 1 13 Electronics 15 2 Technical specification 2 1 Electrical connection 16 2 2 Drive motor power 16 2 3 Work areas 16 2 4 Headstock 16 2 5 Feeds and pitches 16 2 6 Slides 17 2 7 Tailstock 17 2 8 Machine dimensions 17 2 9 Work area 17 2 10 Environmental condit...

Page 3: ...alues for cutting data when turning 41 4 16 Cutting speed table 41 4 17 Terms for the rotating tool 42 4 17 1 Cutting edge geometry for turning tools 43 4 17 2 Types of cutting form levels 43 4 18 Tapping of external and internal threads 45 4 19 Thread types 46 4 19 1 Metric threads 60 flank angle 47 4 19 2 British thread 55 flank angle 49 4 19 3 Indexable inserts 50 4 19 4 Examples for thread cut...

Page 4: ...drawings 76 6 5 Schaltplan Wiring diagram 99 7 Malfunctions 8 Appendix 8 1 Copyright 106 8 2 Terminology Glossary 106 8 3 Liability claims warranty 107 8 4 Storage 108 8 5 Dismantling disassembling packing and loading 108 8 5 1 Decommissioning 109 8 5 2 Dismantling 109 8 5 3 Disassembly 109 8 5 4 Packing and loading 109 8 6 Disposal of new device packaging 109 8 7 Disposal of lubricants and coolin...

Page 5: ...ph Maintenance all maintenance works and functional tests are described which the operator must perform in regular intervals The illustration and information included in the present manual can possibly deviate from the current state of construction of your machine Being the manufacturer we are continuously seeking for improvements and renewal of the products Therefore changes might be performed wi...

Page 6: ...estination the specific applicable regulations of each country must be observed If applicable necessary measures must be taken to comply with the country specific regulations before commissioning the lathe Always keep this documentation close to the lathe If you would like to order another operating manual for your machine please indicate the serial number of your machine The serial number is loca...

Page 7: ...erious injury or death CAUTION A danger or unsafe procedure that can cause personal injury or damage to property ATTENTION Situation that could cause damage to the lathe and the product and other types of damage No risk of injury to persons INFORMATION Practical tips and other important or useful information and notes No dangerous or harmful consequences for people or objects In case of specific d...

Page 8: ...ny operation which is not in accordance with the intended use We expressly point out that the guarantee or CE conformity will expire if any constructive technical or procedural changes are not performed by the company Optimum Maschinen Germany GmbH It is also part of the intended use that you observe the limits of the lathe observe the operating instructions and comply with the inspection and main...

Page 9: ...Risk of fire and explosion due to the use of flammable materials or cooling lubricants Before processing inflammable materials e g aluminium magnesium or using inflammable auxiliary materials e g spirit it is necessary to take additional preventive measures in order to avoid health risks When processing carbons graphite and carbon fibre reinforced carbons the machine is no longer being used as int...

Page 10: ... in a metal working profession is a prerequisite for safe operation of the machine It is essential that the private user is aware of the dangers involved in operating this machine We recommend visiting a training course in the operation of lathes Your specialist dealer can offer you an appropriate training course These courses are also offered by adult education centres in Germany 1 6 2 Obligation...

Page 11: ...esium or using inflammable auxiliary materials e g spirit it is necessary to take additional preventive measures in order to safely avoid health risks 1 9 Safety devices Use the lathe only with properly functioning safety devices Stop the lathe immediately if there is a failure on the safety device or if it is not functioning for any reason It is your responsibility If a safety device has been dea...

Page 12: ...nt of inertia of the lathe chuck and the workpiece The emergency stop button brings the machine to a standstill Turn the knob to the right to unlock and release the emergency stop button CAUTION Only press the emergency stop button in a genuine emergency Do not use the emergency stop button to stop the machine during normal operation Img 1 1 Emergency stop switch 1 9 2 Protective cover of the head...

Page 13: ...chuck protection 1 9 4 Protective cover lead screw and feed rod The lead screw and the feed rod of the lathe is covered with a coil spring as a protective cover Img 1 4 Lead screw and feed rod with protective cover 1 10 Safety check Check all safety devices when starting any work once a week after all maintenance and repair work INFORMATION Use the following summary to perform the checks Lathe chu...

Page 14: ... the lathe in the descriptions for these types of work WARNING Before activating the lathe ensure that this will neither endanger other persons nor cause damage to equipment Avoid any unsafe work methods Make sure that your work does not endanger anyone Clamp the workpiece tightly before activating the lathe Observe the maximum lathe chuck opening Wear safety goggles Do not remove the turning chip...

Page 15: ...f WARNING Live parts and moves of machine parts can injure you or others dangerously If you cannot pull the power plug due to required work e g function check proceed with extreme caution 1 12 2 Using lifting equipment WARNING The use of unstable lifting and load suspension equipment that might break under load can cause severe injuries or even death Check to ensure that the lifting and load suspe...

Page 16: ...nter height mm 158 Distance between centres mm 720 Swing diameter over machine bed mm 310 Swing diameter over cross slide mm 190 Main spindle bore mm 38 Lathe chuck K11 160 D4 bore mm 40 2 4 Headstock Main spindle nose Camlock DIN ISO 702 2 no 4 Main spindle morse taper MT5 Spindle speeds 5 rpm when connecting to 50Hz 165 300 530 750 1400 2400 Spindle speeds 5 rpm when connecting to 60Hz 200 360 6...

Page 17: ...splitting 0 02mm Scale on the handwheel lathe saddle 5mm rev splitting 0 5mm maximum dimension for lathe tool in quadruplicate tool holder mm 25 2 7 Tailstock Quill diameter mm 38 Quill travel mm 70 Taper in the quill MT3 2 8 Machine dimensions Machine Center of Gravity on page 21 Weight kg 260 2 9 Work area Keep a work area of at least one metre around the machine free for operation and maintenan...

Page 18: ...ufficiently dimen sioned industrial truck to the installation site 3 1 1 General risks during internal transport CAUTION DANGER OF TIPPING The device may be lifted unsecured by a maximum of 2cm Employees must be outside the danger zone the reach of loads Warn employees and if necessary advise employees of the hazard Act responsibly during transport and always consider the consequences Refrain from...

Page 19: ...ix days after receipt of delivery Check if all parts are firmly seated 3 2 1 Load suspension point DANGER Danger of crushing and overturning The lathe must be installed by several persons Weight kg 260 Check the horizontal orientation of the base of the lathe with a spirit level Check that the foundation has sufficient load bearing capacity and rigidity Anchor the machine base or the optional mach...

Page 20: ... loads evenly so that the lathe cannot turn over while lifting Make sure that no add on pieces or varnished parts are damaged due to the load suspension 3 2 3 Lifting with a forklift It is recommended that the lathe is transported on the lower portion of the packing crate Disassemble the lateral parts of the packing crate Transporting with a forklift Disassemble the splash board on the lathe Lift ...

Page 21: ...lation of original instruction TU3008G EN TU3008G_GB_3 fm 3 3 Machine Center of Gravity 3 3 1 without a machine base A A A A 240 745 180 185 160 115 210 835 P 13 420 1420 1525 150 665 250 220 Schwerpunkt Centre of gravity 410 550 605 ...

Page 22: ...k area for operation maintenance and repair must not be restricted INFORMATION In order to achieve high levels of functionality and machining accuracy as well as a long service life of the machine the set up location should meet certain criteria The following points should be noted The machine must only be installed and operated in a dry and well ventilated place Avoid places near machines generat...

Page 23: ...faces with a degreaser to soften and remove the protecting greases and coatings Clean all the surfaces with a clean cotton cloth and lubricate the lathe as explained in the following section before connecting the power and beginning to operate the machine 3 5 1 Lubrication When initially lubricating and greasing your new lathe you can check the oil levels through the viewing pane next to the gears...

Page 24: ...e rotary direction switch of counter clockwise rotation L the spindle should rotate counter clockwise If necessary two phase terminals on three phase connector or your three phase connection must be exchanged WARNING The three phase electrical connection may only be performed by an electrician or under the guidance and supervision of an electrician Qualification on page 10 Schaltplan Wiring diagra...

Page 25: ...e headstock 7 Change wheel and feed table 8 Selector switch for feed direction 9 Selector switch for feed speed 10 Selector switch longitudinal feed with lead screw cross feed with feed rod 11 Handwheel lathe saddle 12 Handwheel cross slide 13 Handwheel top slide 14 Longitudinal feed cross feed engagement lever 15 Threading engaging lever 16 Lead screw 17 Feed rod 19 Tailstock 20 Tailstock sleeve ...

Page 26: ...ions rectified promptly Stop the lathe immediately in the event of any abnormality in operation and make sure it cannot be started up accidentally or without authorisation Notify the person responsible immediately of any modification Safety during operation on page 14 4 2 1 Overview of the control elements Speed setting Main switch 1 and Reset of the motor circuit breaker 2 Feed direction 1 Infeed...

Page 27: ...slation of original instruction TU3008G GB TU3008G_GB_4 fm 4 2 2 Overview of indicator elements Tool holder Tailstock Attachment screw lathe saddle 1 Oil sight glass speed gear unit 2 Oil sight glass feed gear Scale cross offset tailstock 2 1 ...

Page 28: ...emergency stop button to the right in order to unlock it Emergency stop switch on page 12 Close the lathe chuck protection Select turning direction Switch on spindle rotation Malfunctions on page 104 Turning direction Spindle rotation On Off Longitudinal feed cross feed Inch thread threads inch Metric thread mm spindle revolution mm per spindle revolution Feed direction Oil fill oiling Position cl...

Page 29: ... motor circuit breaker When the motor has been overloaded Activate the motor circuit breaker again Press the reset button INFORMATION Make sure that the cutting forces are not too large The motor circuit breaker triggers before the three phase motor stops due to overloading or the V belt slips through overload and burns The motor circuit breaker is adjustable You get the highest torque on the spin...

Page 30: ...lathe saddle using the tightening screw Img 4 2 Lathe saddle 4 10 Changing the feed rate 4 10 1 Selector switch Use the selector rotary switches to select the feed direction and feed speed ATTENTION Wait until the machine has come to a complete stop before making any change to the selector levers Img 4 3 Changing the feed rate INFORMATION Use the table on the lathe for selecting the feed speed or ...

Page 31: ...on a quadrant Disconnect the machine from the electrical supply Loosen the locking screw on the quadrant with a hexagon key Img 4 4 Locking screw quadrant Swing the quadrant to the right Remove the lock washers of the clamping screws at the quadrant Remove the screw from the shaft of the feed gear Img 4 5 Attachment of change gears Locking screw Hexagon key Lock washer Screw ...

Page 32: ...d or change gear table and screw the gearwheels onto the quadrant again Swing the quadrant to the left until the gearwheels have engaged again Re adjust gear flank clearance by inserting a normal sheet of paper as an adjusting or distance aid between the gearwheels Immobilise the quadrant with the locking screw Attach the protective cover of the headstock and reconnect the machine to the power sup...

Page 33: ...h any other toothed wheel The lowest gearwheel is moved using the spacer bushing see position 13 on the parts drawing The designation a b c of the change gear table designates the position of the selector lever on the feed gear 4 11 Cross feed longitudinal feed engagement lever ATTENTION Damage to mechanical parts The automatic feed is not designed to move onto mechanical stops or the mechanical e...

Page 34: ... the centering point in order to determine the required height If necessary put the steel washers beneath the lathe tool to achieve the required height Img 4 8 Height up to the turning centre 18mm 4 13 Lathe spindle fixture WARNING Do not clamp any workpieces that exceed the permitted chucking capacity of the lathe chuck The clamping force of the chuck is too low if its capacity is being exceeded ...

Page 35: ...rque must be approximately 80 Nm otherwise the rotational accuracy of the lathe chuck is not present 100 Nm is about the torque used for aluminum rims on cars Img 4 10 Marking clamp bolt 4 13 1 Adjusting the Camlock bolts to the workpiece holder Insert all of the bolts in the screwed flange of the chuck until the reference mark the circular reference line F is in line with the wall of the chuck fl...

Page 36: ... of the clamping jaws is correct if after twisting together of the chuck jaws are centered at the center The clamping jaws and the three jaw chuck are equipped with numbers Nevertheless check before the change if the numbers are readable if necessary check the jaws and their original position Insert the clamping jaws at the correct position and in the right order into the three jaw chuck Do not co...

Page 37: ... cone can be rotated The scaling is performed up to 60 degree of angle It is also possible to adjust the top slide over the 60 angular mark Loosen the two nuts at the left and right of the top slide Swivel the top slide Clamp the top slide again Incorrect Correct Clamping length too short overhang too long Additional support over center or rest Clamping diameter too large Larger lathe necessary Wo...

Page 38: ...t the end of the lathe bed in order to prevent the tailstock from unintentional drawing out of the lathe bed Img 4 13 Lathe bed 4 14 3 Turning of cones with high precision There are different possibilities to machine a cone on a common small lathe 1 By twisting the top slide by setting the setting angle with the angular scale But there the graduation of the scale is too inaccurate For chamfers and...

Page 39: ...h of cut is advanced with the handwheel of the cross slide Img 4 15 Cone setting with stop measure 3 By measuring an existing cone with gauge and stand The stand is put on the top slide The gauge is aligned horizontally and 90 to the top slide The top slide is approximately adjusted to the cone angle and the test prod brought in contact with the cone surface fix the bedslide Now the top slide is t...

Page 40: ...type of cone machining the lowest speed is used Annotation In order to check the position of the tailstock axis to the rotation axis a shaft with two centeringsis clamped between the points The stand with the gauge is put on the bedslide The gauge is aligned 90 to the rotation axis and horizontally brought into contact with the shaft The gauge will pass along the shaft with the bedslide There must...

Page 41: ...e diameter d mm For lathes without continuously adjustable drive V belt drive speed gear the nearest speed is being selected Cutting depth In order to achieve a good chipping the results of the depth of cut divided by the feed shall result in a figure between 4 and 10 Example ap 1 0 mm f 0 14 mm rev and this equals to in a value of 7 1 Feed The feed for rough turning is to be selected in a way tha...

Page 42: ...l X5CrNi1810 X10CrNiMoTi12 30 80 50 140 10 15 Grey cast iron GG10 GG40 15 40 40 190 90 200 70 150 20 30 Cast iron with nodular graphite GGG35 GGG70 10 25 25 120 80 180 60 130 15 25 Copper Brass 40 90 60 180 90 300 60 150 30 80 Aluminium alloys 40 100 80 200 100 400 80 200 40 80 Img 4 18 Geometrically determined cutter for the separation process Img 4 19 Cut and chip size Img 4 20 Cut A A positive ...

Page 43: ...nce the chip drain and the chip shape in order to achieve optimum chipping conditions Examples of types of cutting form levels Wedge angle The following factors influence the chip break when turning Chip angle Setting angle Clearance angle Corner radius r Clearance angle minor cutting edge n Cutting edge geometry Setting angle Cutting speed Vc Setting angle minor cutting edge n Depth of cut ap Poi...

Page 44: ...eed to conduct the chip Img 4 24 Positive apex angle for planing Img 4 25 Neutral apex angle for planing and rough ing Img 4 26 Negative apex angle for roughing The ready ground major cutting edge must be slightly ground with a grindstone for the planing For the roughing a small chamfer must be produced with the grindstone in order to stabilize the cutting edge against striking chips bf f x 0 8 Im...

Page 45: ...d be a strain of the profile Img 4 29 Polished section for threading 4 18 Tapping of external and internal threads Threads with smaller diameters and standard thread pitches should be tapped manually on the lathe with screw taps or dies by turning the clamping chuck as this is more simple to produce CAUTION Pull off the mains plug of the lathe if you want to tap a thread as described above Bolts a...

Page 46: ... UN UNC UNF UNEF UNS M4x12 1 4 20UNC 2A 0 250 UNC 2A Machine tools and general mechanical engineering UNJ UNJ 1 4 20UNJ Aircraft industry and aerospace industry Whitworth B S W W 1 4 in 20 B S W Cylindrical threads Pipe threads or conical pipe threads for thread connections which seal ISO trapezoid thread one and mul tiple threaded TR Tr 40 x 7 Tr 40 x 14 P7 Motion thread Leading spindle and trans...

Page 47: ...lumn 1 Denomination of thread d D pitch P Flank diameter d2 D2 Core diameter Depth of thread Rounding r Core removing hole drill Column 1 Column 2 Bolt d3 Nut D1 Bolt h3 Nut H1 M 1 0 25 0 838 0 693 0 729 0 153 0 135 0 036 0 75 M 1 1 0 25 0 938 0 793 0 829 0 153 0 135 0 036 0 85 M 1 2 0 25 1 038 0 893 0 929 0 153 0 135 0 036 0 95 M 1 4 0 3 1 205 1 032 1 075 0 184 0 162 0 043 1 1 M 1 6 0 35 1 373 1 ...

Page 48: ... 479 37 129 2 760 2 436 0 650 37 5 M 48 5 5 44 752 41 866 41 866 3 067 2 706 0 722 43 M 56 5 5 52 428 49 252 49 252 3 374 2 977 0 794 50 5 M 64 6 60 103 56 639 56 639 3 681 3 248 0 866 58 Metric fine pitch thread Denomina tion of thread d x P Flank dia meter d2 D2 Core diameter Denomina tion of thread d x P Flank diameter d2 D2 Core diameter Bolt Nut Bolt Nut M2 x 0 2 1 870 1 755 1 783 M16 x 1 5 1...

Page 49: ...diameter as BSW Designation 1 8 28 BSP BSPT BSPT British Standard Pipe Taper Thread Conic tube thread cone 1 16 designation 1 4 19 BSPT BA BA British Association Standard Thread 47 1 2 flank angle Common with instruments and watches is being replaced by the metric ISO thread and by the ISO miniature thread It consists of numeric designations from 25 to 0 6 0 mm max diameter Table of the British th...

Page 50: ... direction of the machine spindle is determined when you look into the spindle from the rear side If a left handed thread is to be tapped the feed direction is selected away from the clamping chuck in direction to the tailstock and the machine spindle turns to the right As for thread cutting there are other conditions as for longitudinal turning the forward cutter must show a larger clearance as t...

Page 51: ...gear Img 4 38 Pitch angle Pitch angle Pitch P Core diameter Flank diameter Thread diameter tan P D2 Abb 4 39 Thread cutting The outer diameter had been turned to 30 0 mm and the tool holder is clamped in the quadruple holder for threading aligned angular to the rotation axis The height of centres is checked as described Abb 4 40 radial infeed The depth of thread is manufactured in various passes T...

Page 52: ... switch off the machine at the run out of the thread and cam the cutter out by turning the handwheel of the cross slide Switch the direction of rotation to clockwise rotation Switch the machine on move the lathe saddle to the starting point switch the machine off Radial infeed over the handwheel of the cross slide Switch the direction of rotation to counter clockwise rotation Switch the machine on...

Page 53: ...manent safety device completely covers the protruding workpiece between the tips CAUTION Long workpieces must be additionally supported They are supported by the tailstock sleeve and if necessary a rest with a lathe dog CAUTION When clamping workpieces between the tips of the lathe while using a lathe dog the existing lathe chuck protection must be replaced with a circular lathe chuck protection 4...

Page 54: ...e the hand wheel to move the sleeve back and forth The quill of the tailstock is useable with a drill chuck with countersinking tools INFORMATION Use the longer fixed centring point from the delivery so that the centring point can be pressed out again from the tailstock sleeve INFORMATION When using different tools it can happen that you cannot start with the quill marking with scale value 0 becau...

Page 55: ...ghten the adjusting screws of the tailstock Img 4 44 Cross adjustment of the tailstock INFORMATION The tailstock may be cross adjusted to each direction by approximately 10mm Example A 300mm long shaft is to be taper turned between the centres with an angle of 1 Cross adjustment of the tailstock 300mm x Tan 1 The tailstock must be cross adjusted by approximately 5 236mm CAUTION Check clamping of t...

Page 56: ...Longitudinal turning 4 23 2 Face turning and recessing In the facing operation the tool feeds perpendicular to the axis of rotation of the workpiece Feed is done manually using the cross slide hand wheel The infeed for cut depth is made with the top slide or lathe saddle Img 4 47 Graphic Face turning 4 23 3 Turning short tapers with the top slide Short tapers are turned manually with the top slide...

Page 57: ...way that it coincides exactly with the turning centre The threading engaging lever must be engaged during the whole thread cutting process This does not apply to thread pitches that can be carried out with the thread gauge The thread is produced in various cutting steps in a way that the cutting tool has to be turned out of the thread completely with the cross slide at the end of each cutting step...

Page 58: ...lecting your cooling lubricant The company Optimum Maschinen Germany GmbH does not assume any guarantee for subsequent damages due to unsuitable cooling lubricants The flashpoint of the emulsion must be higher than 140 C When using non water miscible cooling lubricants oil content 15 with a flashpoint ignitable aerosol air mixtures might develop There is a potential danger of explosion The selecti...

Page 59: ...SO 702 2 Size no 4 Maximum clamping diameter mm 160 Lathe chuck passage mm 40 max speed rpm 3000 max static clamping force S kN 24 Maximum torque with lathe chuck key Nm 160 Lathe chuck weight kg 10 Weight of a jaw kg with internal grading 0 318 Mass of chuck jaw set kg 0 954 Centrifugal moment Mc for one jaw kgm with internal grading 0 0164 Gravity distance ro of jaw mm 40 62 D 160 D1 63 513 D2 8...

Page 60: ...urer In order to avoid misuse it is necessary to read and understand the operating instructions before the first commissioning The operators must be qualified Avoiding misuse Improper and unintended use of the manual chuck and disregard of the current safety norms and safety regulations can threaten life and limb of the operator Irrespective of whether our chucks are used under rotation or station...

Page 61: ...afety instructions The permissible speed as per VDI 3106 must be calculated for the machining allowance the maximum guide speed must not be exceeded The calculated values must be tested by performing a dynamic measurement The max guide speed may only be applied with max introduced actuation force and a chuck that is perfect working condition If the chuck is involved in a collision it must be subje...

Page 62: ...tside inwards and with increasing RPM the effective clamping force is reduced by the magnitude of the increasing centrifugal force the forces are opposed When the RPM limit is exceeded the clamping force drops below the minimum clamping force Fspmin Consequently the workpiece is released in an unchecked manner Do not exceed the calculated RPM Do not fall below the necessary minimum clamping force ...

Page 63: ...force for processing a workpiece the centrifugal force of the clamping jaws must be taken into account The permissible speeds can be determined in accordance with VDI Guideline 3106 Determi ning the permissible speed for lathe chucks jaw chucks This guideline also allows for the resi dual tensioning force at a specified speed to be determined Speed n rpm Clamping force F sp kN Required minimum cla...

Page 64: ... the total centrifugal force Fc is multiplied by the safety factor for the clamping force Ssp According to VDI 3106 the following also applies here The total centrifugal force Fc is dependent both on the sum of the masses of all jaws and on the center of gravity radius and the RPM ATTENTION For safety reasons in accordance with DIN EN 1550 the centrifugal force may be a maximum of 67 of the initia...

Page 65: ...ble clamping force of the chuck at a standstill is s 24 kN at a tightening torque of 160 Nm with the lathe chuck key An effective clamping forceFsp of 19 2 kN remains at the chuck see Clamping force speed diagram Lathe chuck K11 160 on page 63 see Basic safety instructions on page 61 WARNING The greater distance above the chuck surface that clamping occurs the lower the clamping force will be 4 25...

Page 66: ... grease from the master jaws In order to maintain the tensioning force and the long term accuracy of the lathe chuck the lathe chuck must be lubricated regularly Insufficient lubrication will result in malfunctions at reduced tensio ning force which affects the accuracy and causes excessive wear and seizing Depending on the chuck type and operating state the tensioning force of a lathe chuck can d...

Page 67: ...orking on the lathe and damage to the lathe Only qualified personnel should carry out maintenance and repair work on the lathe Electrical systems and operating materials may only be installed modified and repaired by a trained electrician or supervised and under the control of a trained electrician and must comply with electrotechnical regulations WARNING Do not climb onto or into the machine whil...

Page 68: ...rge extent on the individual usage and operating conditions Any indicated intervals therefore are only valid for the corresponding approved conditions Interval Where What How Start of work after every maintenance or repair work Lathe Safety check on page 13 Lathe Oiling Oil all guide rails Lubricate the change gears lightly with lithium based grease lubricating Camlock clamp bolt Lathe spindle fix...

Page 69: ...e clearance of the corresponding slideway Img 5 1 Take up screws slideways Start of work after every maintenance or repair work Speed gear unit Visual inspection Check the oil level in the inspection glass of the speed gear unit Img 5 2 auf Seite 70 The oil level must at least attain the centre resp top marking of the oil sight glass Operating material on page 17 Interval Where What How Take up sc...

Page 70: ...ht glass Operating material on page 17 First after 200 hours in service then once a year Speed gear unit Oil change For oil change use an appropriate collecting container with sufficient capacity Unscrew the screw from the drain hole Unscrew the screw from the filler hole Close the drain hole if no more oil drains Fill up to the middle of the reference mark of the oil sight glass into the filler h...

Page 71: ...ole if no more oil drains Fill up to the middle of the reference mark of the oil sight glass into the filler hole using a suitable container Operating material on page 17 Img 5 3 Feed gear When necessary Headstock V belt check re tighten Tighten the V belt set as required Loosen the screws of the motor plate Tense the V belt with the adjustment screws in a way that it can still be pressed down app...

Page 72: ...ck Change gear Oiling Lubricate or fill all oilers with machine oil do not use a grease gun or similar equipment Use the oil bottle in the delivery volume Img 5 6 Oiler cup When necessary Tailstock tighten If the tailstock clamping wears off Shorten the tension way with the take up screw Img 5 7 Tailstock Weekly Lathe chuck Lubricating Lubricating and cleaning the lathe chuck on page 66 Interval W...

Page 73: ... the initial tension of the tapered roller bearings decreases retighten it with the adjusting nut Img 5 8 Spindle bearing Img 5 9 Adjusting nut based on operator s empirical values if necessary in accordance with German DGUV BGV A3 Electronics Electrical inspection Electronics on page 15 Interval Where What How A A A A 38 P 36 P Adjusting nut ...

Page 74: ...echnician can only be made via your specialist dealer If repairs are performed by other qualified technical personnel they must follow the instructions in this operation manual Optimum Maschinen Germany GmbH accepts no liability nor does it guarantee against damage and operating malfunctions resulting from failure to observe these operating instructions For repairs only use faultless and suitable ...

Page 75: ...ure Artikelnummer Article no Die Artikelnummer befindet sich in der Ersatzteilliste The article no is located in the spare parts list Die Seriennummer befindet sich am Typschild The serial no is on the rating plate 6 2 Hotline Ersatzteile Spare parts Hotline Australian Distributor sales machineryhouse com au Australian Distributor service machineryhouse com au New Zealand Distributor service machi...

Page 76: ...g TU3008G DE GB TU3008G_parts fm 6 4 Ersatzteilzeichnungen Spare part drawings A Spindelstock Headstock B Spindelstock Headstock Abb 6 1 Spindelstock Headstock 5 1 2 3 4 6 6 7 8 9 10 11 12 13 14 76 86 87 88 15 15 16 16 17 17 18 19 20 21 22 22 23 24 25 26 ...

Page 77: ...G DE GB TU3008G_parts fm C Spindelstock Headstock Version 1 0 Abb 6 2 Spindelstock Headstock D Spindelstock Headstock Version 1 1 Abb 6 3 Spindelstock Headstock 27 29 30 31 32 33 34 35 36 37 38 39 40 41 42 28 32 34 35 36 37 38 39 40 41 42 31 27 79 80 81 81 82 83 ...

Page 78: ...TU3008G DE GB TU3008G_parts fm E Spindelstock Headstock Abb 6 4 Spindelstock Headstock F Spindelstock Headstock Abb 6 5 Spindelstock Headstock 78 66 68 70 71 72 73 74 75 67 69 67 43 44 45 62 58 57 61 56 55 54 46 47 53 60 63 49 50 65 64 48 51 52 59 77 84 85 ...

Page 79: ... 29 Flansch Flange 1 03427210129 30 Kugellager Ball bearing 1 61804 03427210130 31 Passfeder Fitting key 1 5x5x16 32 Passfeder Fitting key 1 8x7x56 33 Welle Shaft 1 03427210133 34 Zahnrad Gear 1 03427210134 35 Buchse Bushing 1 03427210135 36 Zahnrad Gear 1 03427210136 37 Buchse Bushing 1 03427210137 38 Zahnrad Gear 1 03427210138 39 Sicherungsring Retaining ring 1 20x1 2 40 Kugellager Ball bearing ...

Page 80: ...167 68 O Ring O Ring 2 12 5x1 8 69 Federstift Spring pin 2 5x45 70 Welle Shaft 2 03427210170 71 Sicherungsring Retaining ring 2 15x1 72 Platte Plate 2 03427210172 73 Gabel Fork 2 03427210173 74 Sechskantmutter Hexagon nut 2 M5 75 Gewindestift Grub screw 2 M5x16 76 Klemmmutter Clamp nut 1 03427210176 77 Abdeckung Cover 1 03427210177 78 Feder Spring 2 03427210178 Version 1 1 ab from 2017 79 Riemensc...

Page 81: ...rad Gear 1 75Z m1 5 03427205208 9 Zahnrad Gear 1 45Z m1 5 03427205209 10 Zahnrad Gear 1 80Z m1 5 03427205210 11 Zahnrad Gear 1 20Z m1 5 03427205211 12 Zahnrad Gear 1 85Z m1 5 03427205212 13 Hülse Sleeve 1 03427205204 14 Innensechskantschraube Socket head screw 1 M8x45 15 Schmiernippel Lubrication cup 2 03427205215 17 Innensechskantschraube Socket head screw 1 M6 x 16 18 Zahnrad ohne Abbildung Gear...

Page 82: ...iginalbetriebsanleitung TU3008G DE GB TU3008G_parts fm H Vorschubgetriebe Feed gear Abb 6 7 Vorschubgetriebe Feed gear 1 2 1 64 28 41 60 60 39 39 29 68 30 42 71 71 42 68 30 29 68 71 42 30 31 63 65 56 44 38 56 44 65 72 46 65 34 34 45 ...

Page 83: ...3008G DE GB TU3008G_parts fm I Vorschubgetriebe Feed gear Abb 6 8 Vorschubgetriebe Feed gear 2 2 27 26 6 26 25 1 40 17 16 11 21 24 14 24 23 20 73 22 15 17 19 40 70 66 3 5 9 8 13 12 2 7 10 5 4 37 53 53 20 50 52 51 49 51 48 40 55 24 54 61 32 57 58 36 59 67 18 ...

Page 84: ...9 Gabel Fork 2 03427205329 30 Platte Plate 3 03427205330 31 Bolzen Bolt 1 03427205331 32 Kupplung Clutch 1 03427205332 34 Schalthebel Switch lever 2 03427210167 36 Rutschkupplung Friction clutch 1 03427205336 37 Zahnrad Gear 1 03427205337 38 Abdeckung Cover 1 03427205338 39 Gewindestift Grub screw 2 M6x8 40 Innensechskantschraube Socket head screw 9 M5x8 41 Schraube Screw 10 M5x8 42 Welle Shaft 3 ...

Page 85: ...iginalbetriebsanleitung TU3008G DE GB TU3008G_parts fm J Schlosskasten Apron Abb 6 9 Schlosskasten Apron 36 29 49 8 7 48 44 6 63 5 61 18 52 54 19 32 50 16 17 15 20 47 3 4 30 31 25 22 21 53 62 42 55 65 34 41 40 37 41 51 58 67 1 60 59 ...

Page 86: ...6 2021 09 17 86 Originalbetriebsanleitung TU3008G DE GB TU3008G_parts fm K Schlosskasten Apron Abb 6 10 Schlosskasten Apron 57 35 68 38 33 64 24 64 23 1 39 9 13 12 11 14 10 66 69 28 26 56 2 27 27 10 45 43 45 46 56 ...

Page 87: ... Eccentric 1 03427205433 34 Nabe Collet 1 03427205434 35 Platte Plate 1 03427205435 36 Hülse Sleeve 1 03427205436 37 Gewindestift Grub screw 1 03427205437 38 Zylinderstift Cylindrical pin 2 6x18 39 Gewindestift Grub screw 1 M6x16 40 Feder Spring 1 M6x8 41 Stahlkugel Steel ball 1 03427205441 42 Platte Plate 1 03427205442 43 Zahnwelle Gear shaft 1 03427205443 44 Feder Spring 1 03427205444 45 Flansch...

Page 88: ...inalbetriebsanleitung TU3008G DE GB TU3008G_parts fm L Planschlitten Cross slide Abb 6 11 Planschlitten Cross slide 35 36 27 28 23 26 66 22 23 54 21 24 25 25 17 20 66 60 52 60 18 55 56 64 51 52 60 1 37 53 39 40 41 48 53 38 60 42 43 48 ...

Page 89: ...8 35 Hülse Sleeve 1 03427205635 36 Schraube Screw 03427205636 37 Platte Plate 1 03427205637 38 Platte Plate 1 03427205638 39 Platte Plate 1 03427205639 40 Platte Pa 1 03427205640 41 Abstreifer Wipper 1 03427205641 42 Platte Plate 1 03427205642 43 Abstreifer Wiper 1 03427205643 48 Innensechskantschraube Socket head screw 12 ISO 4762 M4 x 12 51 Innensechskantschraube Socket head screw 4 ISO 4762 M10...

Page 90: ...702 3 Aufnahme Collet 1 03427205703 4 Hebel Lever 1 03427205704 5 Scheibe Washer 1 03427205705 6 Vierkantstahlhalter Toolholder 1 03427205706 7 Oberschlitten Top slide 1 03427205707 13 Keilleiste Gib 1 03427205713 14 Skalenring Scala ring 1 03427205714 15 Führung Giuide 1 03427205715 16 Spindelmutter Spindle nut 1 03427205716 17 Führung Guide 1 03427205715 19 Klemmplatte Clamping plate 1 034272057...

Page 91: ...ng 1 03427205767 68 Rastbolzen Bolt 1 03427205768 71 Spannstift Spring pin 1 ISO 13337 3 x 10 72 Spindel Spindle 1 03427210772 73 Passfeder Fitting key 1 3x10 74 Schmiernippel Lubrication cup 1 03427210774 75 Lagerbock Bearing block 1 03427210775 76 Skalenring Scala ring 1 03427210776 77 Federblech Spring plate 1 03427210777 78 Handrad Handle 1 03427210778 79 Handhebel Handle lever 2 03427210779 8...

Page 92: ...2021 09 17 92 Originalbetriebsanleitung TU3008G DE GB TU3008G_parts fm N Maschinenbett Machine bed Abb 6 13 Maschinenbett Machine bed 1 25 26 14 14 13 43 3 15 2 4 34 28 29 33 35 36 27 16 4 5 40 31 32 41 39 38 4 46 45 ...

Page 93: ...ock Bearing block 1 03427205816 25 Halter Holder 1 03427205825 26 Schraube Screw 2 03427205826 27 Halter Holder 1 03427205827 28 Halter Holder 1 03427205828 29 Halter Holder 1 03427205829 31 Abdeckung Cover 1 03427205831 32 Schraube Screw 4 03427205832 33 Spiralabdeckung Spirale cover 1 03427205833 34 Spiralabdeckung Spirale cover 1 03427205834 35 Spiralabdeckung Spirale cover 1 03427205835 36 Spi...

Page 94: ...ck parts list Pos Bezeichnung Description Menge Grösse Artikelnummer Qty Size Item no 1 Platte Plaze 1 03427205901 2 Gehäuse Housing 1 03427205902 3 Exzenter Eccentric 1 03427205903 4 Platte Plate 1 03427205904 5 Bolzen Bolt 1 03427205905 6 Buchse Bushing 1 03427205906 7 Spindel Spindle 1 03427205907 8 Lagerbock Bearing block 1 03427205908 9 Pinole Sleeve 1 03427205909 10 Klemmplatte Clamping plat...

Page 95: ... 03427205922 23 Passfeder Fitting key 1 DIN 6885 A 4 x 4 x 12 24 Federblech Spring 1 03427205924 25 Gewindestift Grub screw 3 DIN 915 M8 x 30 26 Spannstift Spring pin 1 ISO 13337 4 x 28 27 Sechskantschraube Hexagon screw 1 ISO 4014 M4 x 30 28 Unterlegscheibe Washer 1 DIN 125 A 4 3 29 Hebel Lever 1 03427205929 30 Skala Scala 1 03427205930 31 Skala Scala 1 03427205931 1 2 6 8 3 5 4 7 TU3008G Teileli...

Page 96: ...ende Lünette Fixed steady rest parts list Pos Bezeichnung Description Menge Grösse Artikelnummer Qty Size Item no 1 Feststehende Lünette Steady rest 1 3441461 2 Messingstift Brass pin 3 3 Schraube Screw 3 4 Scheibe Washer 3 8 5 Sechskantmutter Hexagon nut 3 M8 6 Einstellschraube Ajust screw 3 7 Sechskantmutter Hexagon nut 1 M12 8 Scheibe Washer 1 9 Klemmplatte Clamping plate 1 10 Sechskantschraube...

Page 97: ...topper 2 034272003006 7 Buchse Bushing 3 034272003007 8 Platte Plate 1 034272003008 9 Schalter Drehfutterschutz Lathe chuck protection switch 1 Single channel TZ 3112 034272001S4 Schalter Drehfutterschutz Lathe chuck protection switch 1 Double channel TZ 3112 034272001S42K 10 Ring links Ring left 1 034272003010 11 Sechskantmutter Hexagen nut 2 ISO 4032 M6 12 Scheibe Washer 5 DIN 125 A 6 4 13 Senks...

Page 98: ...össe Artikelnummer Qty Size Item no 1 Schild Frontabdeckung Front lable 1 03427210L01 2 Maschinenschild Machine lable 1 03427210L02 3 Drehzahl Schild Rotation speed lable 1 03427210L03 4 Schild Hauptschalter Main switch lable 1 03427200L04 5 Schild Schlossmutter Claps nut lable 1 03427200L05 6 Schild Drehrichtung Rotating derection lable 1 03427200L06 7 Schild Vorschub Feed lable 1 03427200L07 8 S...

Page 99: ...Version 1 1 6 2021 09 17 99 Originalbetriebsanleitung TU3008G DE GB TU3008G_parts fm 6 5 Schaltplan Wiring diagram T Einkanalig Single channel Abb 6 19 ...

Page 100: ... with main switch 1 MP03 034272001S1 1S2 Ein Aus Schalter On Off switch 1 KJD18 034272001S2 1S3 Drehrichtungsschalter Change over switch 1 ZH A 034272001S3 1S4 Schalter Drehfutterschutz Lathe chuck protection switch 1 TZ 3112 single channel 034272001S4 1S5 Not Halt Schalter Emergency stop switch 1 HY57B 034272001S3 1S6 Verriegelungsschalter Schutzabdekkung Interlock switch protective cover change ...

Page 101: ...ch with main switch 1 Kedu RB9 034272001S12K 1S2 Ein Aus Schalter On Off switch 1 KJD18 034272001S2 1S3 Drehrichtungsschalter Change over switch 1 ZH A 034272001S3 1S6 Schalter Drehfutterschutz Lathe chuck protection switch 1 TZ 3112 zweikanalig 034272001S42K 1S4 Not Halt Schalter Emergency stop switch 1 HY57B 034272001S3 1S5 Verriegelungsschalter Schutzabdekkung Interlock switch protective cover ...

Page 102: ...la 150 Meropa 150 VG 100 CLP 100 Aral Degol BG 100 BP Energol GR XP 100 SPARTAN EP 100 Klüberoil GEM 1 100 Mobilgear 627 Shell Omala 100 Meropa 100 VG 68 CLP 68 Aral Degol BG 68 BP Energol GR XP 68 SPARTAN EP 68 Klüberoil GEM 1 68 Mobilgear 626 Shell Omala 68 Meropa 68 VG 46 CLP 46 Aral Degol BG 46 BP Bartran 46 NUTO H 46 HLP 46 Klüberoil GEM 1 46 Mobil DTE 25 Shell Tellus S 46 Anubia EP 46 VG 32 ...

Page 103: ...r broches à haute vitesse VG 68 Deol BG 68 Emergol HLP D68 Spartan EP 68 Drucköl KLP 68 C Shell Omala 68 Fett für Zentralschmierung Fließfett Grease for central lubrica tion Graisse pour lubrification centrale NLGI Klasse 000 NLGI class 000 ARALUB BAB 000 Grease EP 000 Shell Gadus S4 V45AC CENTO PLEX GLP 500 Mobilux EP 023 Multifak 264 EP 000 Fett für Hochfrequenzspin deln Grease for Built in spin...

Page 104: ...lamp lathe tool with less overhang Reduce feed Increase radius V belt squeaks V belt slips V belt wear down V belt tension is too loose V belt check re tighten on page 71 Speed of rotation varies too much Workpiece becomes conical Centre are not aligned tailstock off set Top slide is not exactly set to zero when turning with the top slide Align the tailstock to the center Align the top slide exact...

Page 105: ...athe tool is clamped incorrectly or grinding has been started the wrong way Wrong pitch Wrong diameter Set the lathe tool to the centre grind angle correctly Use 60 lathe tool for metric threads 55 lathe tool for inch thread Adjust right pitch Turn the workpiece to the correct diameter Malfunction Cause possible effects Solution ...

Page 106: ... screw Threaded shaft for tapping threads Feed rod Shaft without threads for transferring the feed to the saddle or cross slide Lathe chuck Clamping tool for holding the workpiece Drill chuck Drill bit adapter Lathe saddle Slide on the slideway of the machine bed which feeds parallel to the tool axis Cross slide Slide on the slideway of the machine bed which feeds parallel to the tool axis Top sli...

Page 107: ...echnical options and proper use in particular due to over straining of the machine Any defects arising by one s own fault due to faulty operations or if the operating manual is disregarded Inattentive or incorrect handling and use of improper equipment Unauthorized modifications and repairs Insufficient installation and safeguarding of the machine Disregarding the installation requirements and con...

Page 108: ...e management If appropriate call on the help of a specialist waste disposal company for the treatment of the material Please make sure that electrical components are disposed of professionally and in accordance with the statutory provisions The machine contains electrical and electronic components and must not be disposed of as household waste According to the European directive 2011 65 EU regardi...

Page 109: ...ed to be supplied to the material reuse The packaging wood can be supplied to the disposal or the reuse Any packaging components made of cardboard box can be chopped up and supplied to the waste paper collection The films are made of polyethylene PE and the cushion parts are made of polystyrene PS These materials can be reused after reconditioning if they are passed to a collection station or to t...

Page 110: ...of raw materials For further information about the recycling of this product please consult your District Office municipal waste collection station or the shop where you have purchased the product 8 9 Product follow up We are required to perform a follow up service for our products which extends beyond shipment We would be grateful if you could send us the following information Modified settings A...

Page 111: ...e been applied EMC Directive 2014 30 EC Restriction of the use of certain hazardous substances in electrical and electronic equipment 2015 863 EU The following harmonized standards were applied EN ISO 23125 2015 Machine tools Safety Turning machines EN 60204 1 2014 Safety of machinery Electrical equipment of machines Part 1 General requirements EN 13849 1 2015 Safety of machinery Safety related pa...

Page 112: ...esting Zeichnung Drawing Zulässig max admissible tolerance mm Messwert Measured value mm 1 Axialruhe und Rundlaufgenauigkeit der Drehspindel Run out of spindle and periodical radial slip of spindle A 0 009 B 0 009 A B 2 Rundlauf genauigkeit der Drehspindel aufnahme Run out of spindle nose 0 009 3 Rundlaufgenauigkeit des Innenkegels der Arbeitsspindel Run out of internal taper of spindle A 0 015 B ...

Page 113: ... MT 2 centres for same height above reference plane A 0 03 A 6 Parallelität der Arbeitsspindel A senkrecht B waagrecht Parallelism of spindle axis with carriage movement A vertical plane B horizontal plane A 0 03 250 B 0 03 250 A B 7 Parallelität des Oberschlittens zur Arbeitsspindel und Bettschlittenbewegun g Parallelism of of top slide with spindle and carriage movement 0 04 75 Nr No Testobjekt ...

Page 114: ...Drehfutter Prüfdorn A 20mm B 30mm Run out of yaw chuck Object of testing A 20mm B 30mm A 20mm 1 0 04 2 0 08 100 B 30mm 1 0 04 2 0 08 100 A 1 2 B 1 2 Nr No Testobjekt Object of testing Zeichnung Drawing Zulässig max admissible tolerance mm Messwert Measured value mm ...

Page 115: ... Inch thread 49 Indexable inserts 50 Indicator elements 27 Inspection 67 L Lathe chuck 60 Lathe chuck protection 13 Load suspension point 19 Longitudinal turning 56 Lubrication 23 M Maintenance 67 Mechanical maintenance 15 Metric threads 47 Misuse 9 Motor circuit breaker TU3008G Reset 29 Mounting rests 53 O Obligations User 10 P Protective equipment 14 Protective cover feed rod 11 headstock 12 lat...

Page 116: ...Version 1 1 6 2021 9 17 116 Translation of original instruction TU3008G GB TU3008G_GBSIX fm ...

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