WLLOUGHBY COMMUNTY MEN'S SHED mens 296C Salors Bay Road, l _ L^ NORTHBRDGE N.S.W 2063 The Wlkmghby Communty" NSTRUCTON MANUAL BENCH LATHE Before usng be sure to read ths manual carefully -C6-
Safety nstructons For Lathe. MAKE SURE ALL GUARDS are n place and that the lathe sts on a flat, stable surface. 2. BEFORE STARTNG THE LATHE be certan the workpece has been properly engaged n the chuck, talstock, center, and that there s adequate clearance for full moton. 3. ADJUST TOOL POST to provde proper support for the turnng tool you wll be usng. Test tool post clearance by rotatng workpece by hand before turnng lathe on. 4. SELECT THE TURNNG SPEED whch s approprate for the type of work, materal, and tool bt. Allow the lathe to gan ts full speed before begnnng a cut. 5. NEVER REVERSE MOTOR DRECTON whle the lathe s n moton. 6. DO NOT STOP LATHE USNG YOUR HAND aganst the workpece or chuck. 7. DO NOT LEAVE LATHE RUNNNG UNATTENDED for any reason. 8. NEVER LEAVE A CHUCK KEY N THE LATHE CHUCK. 9. NEVER OPERATE THE LATHE WTH DAMAGED OR WORN PARTS. Mantan your lathe n proper workng condton. Perform routne nspectons and mantenance promptly when called for. Put away adjustment tools after use. 0. MAKE SURE LATHE S TURNED OFF, dsconnected from ts power source and all movng parts have come to a complete stop before startng any nspecton, adjustment, or mantenance procedure.. KEEP LOOSE CLOTHNG ARTCLES such as sleeves, belts or jewelry tems away from the lathe and drll spndles. 2. ALWAYS USE THE PROPER CUTTNG TOOLS for the materal you are turnng, make certan they are sharp and that they are held frmly n the tool post. 3. ALWAYS PLACE A BOARD OR PECE OF PLYWOOD ACROSS THE BEDWAY when removng or nstallng chucks to avod the possblty of a fnger pnch occurrng between a loose chuck and the edges of the bedway. CAUTON No lst of safety gudelnes can be complete. Every shop envronment s dfferent. Always consder safety frst, as t apples to your ndvdual workng condtons. Use ths and other machnery wth cauton and respect. Falure to do so could result n serous personal njury, damage to equpment or poor work results. WARNNG Lke all power tools, there s danger assocated wth the Lathe. Accdents are frequently caused by lack of famlarty or falure to pay attenton. Use ths tool wth respect and cauton to lessen the possblty of operator njury. f normal safety precautons are overlooked or gnored, serous personal njury may occur. GROUNDNG n the event of an electrcal short, groundng reduces the rsk of electrc shock by provdng a path of least resstance to dsperse electrc cur rent.the outlet must be properly nstalled and grounded n accordance wth all local codes and ordnances.
Test Run Lathe Before contnung to Operate, test run the lathe to make sure t runs properly. To test run the lathe:. Make sure that there s NOT a chuck key nserted n the chuck, and that the lathe eyesheld s n the down poston over the lathe chuck. Make ths step a habt that you perform every tme you start the lathe. 2. Famlarze yourself wth the lathe controls shown n Fgure below. Make sure the STOP button s all the way down before contnung. 6. Turn the FWD/REV swtch clockwse. Ths should make the lathe chuck turn clockwse when you start the machne. 7. Flp up the emergency stop button to reveal the red and green ON/OFF buttons. 8. Stand to the sde of the lathe chuck lne of rotaton, and press the green button to turn the lathe ON. f the carrage starts movng, mmedately push the STOP button and dsengage the carrage feed lever, then restart the lathe. 9. Allow the lathe to run for at least two full mnutes to make sure t s runnng satsfactorly. 0. Press the lathe emergency stop button to turn the lathe OFF.. After the lathe chuck has come to a complete stop, turn the FWD/REV swtch counterclockwse. 2. Stand to the sde of the lathe chuck lne of rotaton, and press the green button to turn the lathe ON. 3. Allow the lathe to run for at least two full mnutes to make sure t s runnng satsfactorly. 4. Press the emergency stop button to turn the lathe OFF. Lathe controls 3. Plug the lathe nto the power outlet! 4. Move the carrage feed lever up to the dsengage mode. t s mportant that the carrage feed s NOT movng and s n the neutral poston untl later. 5. Turn the to left Selector swtch to the "CUT TNG" poston. The lathe power ndcator lght should lght up. Note f t s does not lght up, unplug the machne and check the fuse, your power source, and the connectons on the machne before attemptng to start the lathe. Call our servce department f you cannot easly resolve the ssue. 5. After the lathe has come to a complete stop, engage the carrage handwheel, rotate the handwheel to center the carrage on the bed, then dsengage the handwheel. 6. Engage the automatc carrage feed lever. 7. Stand to the sde of the lathe chuck lne of rotaton, and press the green button to turn the lathe ON. 8. Verfy that the carrage moves along the bed, and press the emergency stop button to turn the lathe OFF. -4-
OPERATONS To get the most out of your machne, please take the tme to famlarze yourself wth the varous controls as shown n Fgures below. nstallng Talstock Dead Center There are 2 dead centers ncluded wth the Lathe. The smaller dead center s a MT#2 (Morse Taper) and fts n the talstock barrel. To nstall the talstock dead center:. Famlarze yourself wth the talstock components shown below. Lathe controls Talstock components Lathe components 2. Make sure that the MT#2 dead center and talstock barrel are clean and free of any drt, dust, grease or ol. These parts wll last longer and reman accurate when properly cleaned before each assembly. Morse tapers wll not nterlock when drt or ol are present on the mountng surfaces.
3. nsert the end of the dead center nto the talstock barrel, as shown below, untl t seats tght enough that t wll not rotate when turned by hand. Note do not worry about pushng the dead center nto the barrel too far. The force of the center contactng a mounted workpece wll fully seat the taper when the handwheel s tghtened. 4. Tghten the barrel lock to prevent the talstock barrel from movng durng operaton. Adjustng Talstock Longtude Poston The talstock on the Lathe clamps to the bed wth the nut shown below. Ths nut allows the tal - stock to be postoned longtudnally along the bed and then locked n place. nsertng dead center nto talstock barrel Talstock clamp bolt To adjust the talstock longtude poston: Removng Talstock Dead Center. Use a 7mm wrench to loosen the talstock clamp bolt. 2. Wth your hands, move the talstock nto poston along the bed. To remove the talstock dead center: 3. Tghten the talstock clamp bolt to secure the talstock nto poston.. Use the barrel handwheel to move the talstock barrel all the way back nto the talstock untl the handwheel wll no longer turn. 2. Pull the dead center out of the talstock barrel. -6-
Adjustng Cross Slde Adjustng Compound Slde The cross slde s only desgned to move perpendcular to the longtudnal axs of the lathe, and t features a scale on the handwheel that dsplays graduatons of one thousandths of 25mm (0.025mm). To adjust the cross slde:. Usng the handwheel, back the cross slde away from your startng pont by at least 0.4mm, then move the cross slde forward to your startng pont. Note ths procedure wll clear any free movement (or backlash) n the lead screw so your handwheel scale readng wll be accurate. Smlar to the cross slde, the compound slde features a scale that dsplays graduatons of one thousandths of 25mm(0.025mm). Unlke the cross slde, the compound slde can be rotated to a set angle and then t can be moved back and forth along the axs of that angle. To adjust the compound slde:. Loosen the compound slde bolts shown below to allow t to be rotated. 2. Hold the handwheel stll and turn the scale so the "0" mark lnes up wth the ".000" mark on the cross slde, as shown n Fgure below. As long as you avod backlash by contnung to move the cross slde n the same drecton, the scale on the handwheel wll be accurate. Compound slde bolts 2. Rotate the compound slde to the angle needed for your procedure. 3. Tghten the compound slde bolts, and check the angle agan to make sure t dd not move durng tghtenng. Adjustng handwheel scale 3. After movng the cross slde backward after your operaton, remember to clear the backlash before movng the cross slde forward to the "0" mark for the next cut. 4. Use the compound slde handwheel to move the tool back and forth along the axs of the new angle. Smlar to adjustng the cross slde handwheel, make sure the threads are engagng and all backlash has been cleared before you set the handwheel scale to "0", or t wll not be accurate.
Adjustng Carrage Lke most lathes, the longtudnal movement of the carrage (carrage feed) on the Lathe can be controlled both manually and automatcally. Before proceedng, take a closer look at the carrage controls shown below To use the automatc carrage feed:. Select the desred feed rate you need by lookng at the charts on the lathe drve cover. When new, The Lathe s geared for a carrage feed rate of 0.mm per revoluton. Use the manual feed handwheel to poston the carrage to your desred startng pont and set the scale on the handwheel to "0". 2. Move the carrage feed lever down to engage the half-nut, whch n turn, makes the automatc carrage feed actve. 3. Pull out the carrage manual feed handwheel to unlock t so t does not rotate when the automatc carrage feed s engaged. The carrage feed wll now move forward or backward, dependng on whch drecton you have selected for lathe rotaton. Carrage controls To move the carrage feed manually:. Push the carrage feed handwheel toward the carrage to engage the gear on the lead screw. 2. Rotate the handwheel clockwse to move the carrage rght and rotate the handwheel counterclockwse to move the carrage left. 3. Set the handwheel scale n the same manner as descrbed n the "Adjustng Cross Slde" nstructons, and be sure to account for the backlash. -8-
Understandng Gear Charts Threadng Charts By arrangng the gears as shown on the charts, you can set up the carrage feed to cut any of the thread ptches dsplayed. See below. The Lathe can be geared for a varety of dfferent feed rates, so charts are placed on the drve cover of the lathe that explan how to set up the gear combnatons for each type of carrage feed applcaton. These applcatons are broken nto two categores of charts turnng and threadng. Turnng Chart The speeds gven on the turnng chart represent standard speeds for most types of turnng applcatons. See below. mm/ Ax 0.4 0.5 0.6 0.7 0.8 G D F E 30 80 L^G mm/ Ax 30 60 30 50 G 52 42 60 60 80 G 66 60.25.5.75 2 2.5 3 G D G 52 G 66 G 70 F E 75 80 75 80 70 80 80 75 80 L^G 60 G 50 G 40 G G 40 30 G 75 25 \ mm. VW\ /o 0. 0.2 V D 33 80 50 80 F E G L 90 25 G 90 Turnng chart 90 33 G 90 7n XX G D F L G E 66 0 4 9 40 60 40 52 G 52 G 7n +-+ AA G D G 60 F L G E 66 75 50 66 G 50 40 20 22 40 44 52 G 80 60! 80 52 G 33 52! 30 52 Threadng charts
Ths s how to read the feed rate charts:. The box n the upper left-hand corner of each chart tells whether that chart represents carrage feed movement for standard or mperal threads. These boxes are shaded below. 3. The boxes on the left-hand column (excludng the box n the upper left-hand corner) represent the gear postons on each shaft. These boxes are shaded below and the shafts are called out wth arrows. mm -H- AA.25.5.75 G D G 52 G 66! F E 75 80 75 80 70 80 L G 7n u 60 G 50 G 0 40 G G D F E 66'40 60 40 The shaded box ndcates whether the chart s for standard or mperal threads. The boxes n the top row of each chart (excludng the box n the left-hand corner) shows the thread ptches lsted on that chart. These boxes are shaded below. Upper Adjustable Shaft Lower Adjustable Shaft Pvot Shaft mm xx 0.4 G D F t E L^G 30 80 The shaded boxes show the thread ptches lsted on ths chart Each shaft has room for two postons to mount the gears a forward poston and a rear poston. Fgure below separates these postons nto dfferent shades for you to understand better. mm tx 0.4 0.5 0.6 0.7 0.8 G D G 52 G 66 F E G 30 80! 30 60 30 50 42 60 60 80 60! mm M.25.5.75 G D G 52 G 66 F E L^G 75 80 60 G Rear - Forward 75 80 50 G 70 80 40 G The shaded boxes show the thread ptches lsted on ths chart The shaded boxes show the thread ptches lsted on ths chart Both forward and rear postons must be flled on the shaft n order for the gears to work properly. A good example of ths s the blank spot "G," as shown n the chart above. Although the chart shows ths as a blank spot, there should actually be a spacer n ths poston on the machne. Ths spacer s only reflects ACTVE gear postons. -0-
NOTCE On some setups, smaller gears must be used as spacers on the adjustable shafts. 5. The lnes between gears "D" & "E" and gears "F" & "L" on the chart below ndcate where the gears should be n mesh. Here s a real-world example of a gear setup as shown on the chart: When the lathe s shpped from the factory, t s geared for a carrage feed rate of 0. mm per spndle revoluton, or the gear combnaton shaded below. mm AA G D F E L^G 0.4 0.5 0.6 30 80 30 60 30 50 m m. W V \ / o 0. 0.2 V D 33 80 F E G L 90 25 G 90 50 80 90 33 G 90 Chart showng gear setup for 0.mm The shaded boxes hghlght the gear mesh lnes 6. The boxes shaded below represent the actual gear combnatons requred to cut the thread ptches. Fgure below shows a profle of the 0.mm feed rate actual gear setup on the machne. Notce how the gears mesh together n the locatons dsplayed on the chart. mm.25.5.75 2 2.5 3 G D G 52 G 66 j G 70 F E 75 80 75 80 70 80 80 [ 75 80 75 25 60 G 50 G 40 G G 40 30 G The shaded boxes show specfc gear setups Actual gear setup for 0.mm feed rate --
Reverse Threadng 3. Thread the extra fxed-shaft gear nto mountng locaton "A" as shown below. The Lathe can be setup to turn left-handed threads by addng another fxed-shaft gear and movng the orgnal fxed-shaft gear to another mountng locaton. Fgure below shows the three mountng locatons for fxed-shaft gears (spndle drve pulley s removed for clarty). For llustraton purposes, we label these mountng postons A, B &C. Extra fxed-shaft gear mounted n poston "A" Fxed-shaft gear mountng postons To set up the gears for reverse threadng:. Dsconnect the lathe from the power source! 2. Locate the extra fxed-shaft gear (shown n Fgure below ) n your nventory of loose parts. -2- Extra fxed-shaft gear
4. When the machne s shpped, a fxed-shaft gear s n poston "C." Remove that fxedshaft gear from mountng locaton "C" and thread t nto mountng locaton "B" as shown below. 6. Tghten the cap screw n the gear bracket to keep t from pvotng. 7. Spn the lathe chuck by hand to ensure that the gears do not bnd. Fxed-shaft gear mounted n poston "B" 5. Loosen the cap screw on the gear bracket, and pvot the bracket so the top gear meshes wth the fxed-shaft gear that s n poston "B," as shown below.! \ All gears n mesh for reverse threadng operatons 8. Replace the cover and test run the machne before proceedng wth your specfc operaton. -3-