| MAXIMAT SUPER 11 Instruction book Service parts Englisch Order No. ENS 810 Auflage: 10. 9. 8 7. 6 5. 4. Maier+Co. 92 91 90 89 88 ‘A-5400 Hallein/AustniaCAUTION: READ THIS! Berore TURNING HAND- WHEELS OR CRANKS... @ Avoid damaging precision surfaces and parts. @ Carriage andtailstock are LOCKED TO BED andshouldnotbe moved until bed is cleaned. Check bags and cartons for parts. Read all instructions — a few minutes now may save hours later. Clean the lathe — machined surfaces are coated with rust preventive which must be removed — see CLEANING. Handle with care — this lathe is a precision machine. Follow safety rules for power tools. Turn off motor before attempting adjustments or maintenance. @ Be sure work piece is firmly supported on the lathe. @ Keep the lathe clean, lubricated, and adjusted as instructed. ® Donotleave cleaning rags, tools or other materials onlathe bed or around moving parts of the lathe. Before operating the machine, fill oil into head- stock and gearbox, 0,5 Liter each. Oil quality: EMCO Special Oil (Order No. 751 000, 4 bottles) or oils as recommended in the lubrication chart.SAFETY RULES FOR POWER TOOLS 1. KNOW YOUR POWER TOOL Read the owner’s manual carefully. Learn its ap- plication and limitations as well as the specific potential hazards peculiar to this tool 2, GROUND ALL TOOLS I tool is equipped with three-prong plug. it should be plugged into o three-hole receptacle. If adapter is used to accommodate 1wo-prong receptacle, the adapter wire must be attached 10 ‘known ground, Never remove third prong. 3. KEEP GUARDS IN PLACE ‘and in working order. 4, REMOVE ADJUSTING KEYS AND WRENCHES Form habit of checking to see that keys and ad. justing wrenches are removed from tool before turning on tool. 5. KEEP WORK AREA CLEAN Cluttered areas and benches invite accidents. 6. AVOID DANGEROUS ENVIRONMENT Don't use powar.tools in damp or wet locations. Keep work area well illuminated. 7. KEEP CHILDREN AWAY All visitors should be kept o safe distance from work area. 8. MAKE WORKSHOP KID PROOF — wlth padlocks, master switcher, or by ro moving starter keys. 9. DON'T FORCE TOOL It will do the job better and be sofer at the rate For which it was design: 10. USE RIGHT TOOL Don't force tool or attachment to do a job it was not designed for. 11. WEAR PROPER APPAREL No loose clothing or jewelry to get caught in moving parts. 12. USE SAFETY GLASSES Also use face or dust mask if cutting operation is dusty. 13. SECURE WORK Use clamps or 0 vise to hold work when proc tical. I's safer than using your hand, frees both hhands 10 operate tool. 14, DON'T OVERREACH Keep your proper footing and balence ot oll times. 15. MAINTAIN TOOLS IN TOP CONDITION Keep tools sharp and clean for best and safest performance. Follow instructions for lubri- ‘cating and changing accessories. 16. DISCONNECT TOOLS: before servicing and when changing acces- sories such as blades, bits, cutters. 17. AVOID ACCIDENTAL STARTING Make sure switch is “OFF” before lugging in 18. USE RECOMMENDED ACCESSORIES Consult the owner's manual. Use of improper ‘accessories may be hazardous, 19. TURN SPINDLE BY HAND BEFORE SWITCHING ON MOTOR This ensures that the workpiece or chuck jaws will ot hl the lathe bed, saddle or erosslide,and also ‘ensures that they clear the cutting too, 20.CHECK THAT ALL HOLDING, LOCKING AND DRIVING DEVICES ARE TIGHTENED 21.COVER EXTENDING PARTS When working on tubes or pipes which extend tothe side of the headstock, these must be covered over the whole lenght22, REMOVING CHIPS For removing chips, use a chip hook For reasons of betterilustration, the chip guardand chuck quard are not always mounted. Chuck guard ‘and chip quard should, however, be used whenever possible. — 23, DISMOUNTING COVERS Before dismounting electrical housing cover, front plate on headstock and front plate on gearbox, disconnect electrical supply. The operation of any power tool can result in foreign objects boing thrown into the oyes, which can result in severe eye damage. Always wear safety glasses or eye shieldsbefore com- mencing power tool operation. We recomm- end Wide Vision Safety Mask for use over spectacles, or standard safety glasses, a coles Saat LOEW The machine is built in different versions so, if there is no influence on explanations, the photos do not always correspond with the machine delivered. Lubricate machine regularly to lubrication plan (see page 32—34).v Technical Data — Lathe Center height 5.5") 140mm Feeds Distance between centers (25.6%) 650 mm_| Metric machine: Sana oerbed 14 longitudinal (.00118-901:8inehiex) 0,08~0,3 mmvrev. 14 transversal (2.00050-0.0059neniew) 0,015~0,15mmvrey. Swing over cross side (677) 170mm _[~inch type machine: Width of athe bed (6.1) 15S mm] 15 longitudinal 0,0018-0,0128 inchirev. “Travel ofthe top side 3.9") 100 mm }_15 transversal 0,0008-0.064 inctvrev. Travel of cross side 63 ‘Thread pitches metric machin Leadscrew diameter © 14 metric threads (0,01-0,1") 0,252.5 mm (wi i—N 22) Self-centering chuck diameter Siinch threads 9-96 tp. Independent chuck diameter with change gear set adaitonally Faceplate diameter 13 metic threads (0,005~0,18") 0,125-5 mm Net weight (without machine stand) ‘approx 170 kg ]_29 inch threads 29-78 tpi Net weight (with machine stand ‘approx 243g | 12 Module threads 25 Diam, piteh Fawasioee Thveed ones neh ype madi Hole through spindle {1,0°) 26 mm 6 metric threads (0,0059-0,078") 0,15-2 mm 15 non ven 91 wth cnonge gos 8 acionay Sole as TE TOON SSO SE rrinen eoes v25-41pi 13 metic theeads (0,01-0,24") 29 Diam. pitch 7 Module tveads Talistock — Drive Motor Genter sleeve damater TET SO mm |_Motor rating S-phase version) (S6-60%) 1,1 RW, RW Stroke of center sieave {3.1 7) 80 mm | Motor rang (T-phase version) (S6—60%) 0,75 RW,OKW inside taper wiz] Soeeds 45072626 p.m Se-over TOAOT) SiO mmsb mm | Required foor space (55x35) "500x900 mm ‘Number of spindle speeds a Range of speeds SS_2DOU EBA. Vertical Milling and Drilling Unit Maximum neight between, table (cross sie) and spindle nose (12°) 305 mm Throat 7 (6.7) 163 mm Spindle taper MT2 Stroke of quill 8) 40mm Data subject to change. Motor rating, 1-phase™ (S 3=60%) ra Motor rating, S-phase (S 360%) 0,30 KW Range of spindle speeds 1202000 p.m. Weight ‘approx. 43 Kg ~ ieee sine valage and Feavaney when Oarbn Dimensions ___ 138 (5451 0495) 6 25.6" )% Foundationplan 270, | I | q 3 g A 298 - _ 8251995) | 129511405), —__| 1166 (45,9")|. “Standard” Electric Version Different Versions of the Basic Machine ‘the mechanical elements electrical safety regu- of the MAXIMAT SUPER 11 lations in the countries basic machine are the supplied, three differ- same on all machines. ent versions are avail- Due to the different able. iva) Pes 1. Switch for two 1, Switch for two speeds and two speeds and two turning directions Clamping strip for: turning directions 2. Clamping strip for: power supply power supply connection of Ver~ tical milling and connection of Ver~ tical milling and drilling unit drilling unit connection of connection of coolant attachment coolant attachment connection of connection of machine lamp machine lamp + Motor 3. Motor + Il. “VDE” Electric Version 4. Lockable main switch| with Emergency Stop function and low- volt release Ml “Special Safety” Electrical Version switch for two speeds and two turning directions + Clamping strip for: power supply connection of Ver~ tical milling ana drilling unit connection of coolant attachment connection of machine lamp + Motor Lockable main switch with Emergency Stop function and low- volt release 5 8. 9. to. ‘Thermal overload relay for main motor Thermal overload relay for vertical unit motor ‘Thermal overload relay for coolant attachment Fuse for short cir- cuit protection of machine lamp Fuse fur short cix~ cuit protection of control circuit. Microswitch prevent- ing unintentional opening of gear cover.Basic Equipment Bed with Vee-guideways Headstock Tailstock Longitudinal, cross and top slide Single toolpost Gearbox Leadscrew Feedshaft Set of wrenches Unpacking the Machine The machine is delivered packed in a wooden crate. After receipt check all parts for completeness. The machine can best be lifted out of the crate with a belt or rope, which is fixed around the diagonal rib of the lathe as illustrated. Not weight of machine: ap.167 kg (368 pounds) Drive motor completely installed, with operating switches and electrical housing 1 center mr4 1 Center mr2 Lathe dog Dog pin Grease gun Instruction Book Service Parts List Cleaning the Machine All blank surfaces of the machine are coated with a rust-protective. This must be carefully removed with petrol or similar material; do not use nitrobezine. After this, all parts must be coated with a rust- preventive oil. Por transport reasons, the longitudinal slide is clamped to the lathe bed and must not be moved before the rust-protective is removed.Setting-up the Machine General only an accurately alignea machine guarantees maximum precision. The lathe bed must be levelled exactly in longitudinal and cross directions. Levelling devices with the accuracy noted below have to be used. Allowable deviations: 9,02 = 0,05 mn/m Note: Workbench or support area must be comparable to the weight of the machine. Mounting the Machine to an Already Existing Workbench 334 (137) 127 677 345 (14°) — Four casting extensions are provided on the bottom of the lathe bed. These are used for supporting and levelling the machine be means of set screws in longitudinal and cross directions. Recommended size of set screws: M1o (3/8") 675 (206) 1370 (54°) Recommended Method_of Pastening the Machine sting extensions for set screws @ "uv" on the lathe bed for tightening the machine© Tightening screw, recommended size: M1o (1/2") Base of lathe bed Setting screw Steel plate Recommended thickness of steel plate: ca.2omm (0,8") These 2 steel plates must be fixed to the workbench. ©e5 Note: Before bolting down the machine, be sure that all 4 set screws rest against the lathe bed, otherwise the bed would be distorted or bent through the bolting down. Mounting: Machine to Machine Stand, Vertical Milling and Drilling Unit and Splashguard. 1. Assembly of the Machine Stand The sizes of the screws, nuts and washers as well as way of assembly are indicated in Spare Parts List. 2. Aligning and Fixing the Machine Stand: Method 1 The machine stand is aligned by means of the hexacon screws under which steel plztes must be placed. Then the machine stand is fixed with dowel bolts or similar. Method 2: The machine stand is aligned with levelling elements. The levelling elements re~ place bolting to the floor. [o)3. Mounting the Machine to the Machine Stand: The machine is placed onto the nachine stand and is levelled in longitudinal and cross directions by means of the 4 levelling bolts at exact horizontal position. Then the machine is fixed to the stand with the 2 hexagon bolts. Note: Before bolting down the machine, all 4 levelling bolts must rest against the casting ex- tensions, otherwise the bed vould be distorted or bent. 4, Mounting the Vertical oi ig Unit The vertical milling and drilling unit is delivered with its own Instruction Manual and Spare Parts List. In this Instruc- tion Manual the mounting, service, tools and accessories are described in detail. For the electrical connection of the vertical unit, see page 12 10 5. Mounting the Splashguard The sizes of screws, nuts and washers are indicated in the Spare Parts List.Electrical Connections NOTE: THE ELECTRICAL CONNECTIONS MUST BE CARRIED OUT PROFESSIONALLY. A GROUNDING RECEPTACLE MUST BE AVALLABLE. SHOULD AN ELECTRICAL FAILURE OCCUR IN THE MOTORS, THE GROUNDING PLUG AND RECEP- TACLE WILL PROTECT THE USER PROM ELECTRICAL SHOCK. IF A GROUNDING RECEPTACLE IS NOT AVAILABLE, USE A GROUNDING ADAPTOR TO ADAPT TO PROPERLY GROUNDED RECEPTACLE. THE MACHINE Nor NEVER USE IF If IS NOT PROPERLY GROUNDED! Fitting bores are provided on the bottom of the electrical housing for the electrical connections. One of them is provided with a screw-type conduit fitting. The other four bores are for the connection of the acces- sories and are plugged. The screw-type conduit fitting provided in the electrical housing is intended for the power supply of the machine. Serew-type fittings for the vertical unit and other accessories are packed with the separate accessories u Bores for: 1. Vertical milling and drilling unit 2. Power supply 3. Cable for main motor, already installed 4. Coolant attachment 5. Machine lamp 6. Extra 7. Clamping strip numbers (note the on the strip) 8. Grounding strip CORRECT MOUNTING OF THE SCREW-TYPE CONDUIT FITTING The basic element (1) and the nut (2) are mounted to the electrical housing. The thread lock nut (3), the cone element (4) and the rubber ring (5) are threaded onto the cable. After clamping the cable ends, the rubber ring and the cone element are pressed into the basic element; the cable is then fixed by tightening the thread lock nut.Electrical Connection — Single-phase 1. POWER SUPPLY Required cable section: 3.x 1,5 mm? ( (up to 10 m cable length) 3.x 2,5 mmé ( (over 1o m cable length and with voltages 100 V, 10 V and 115 Vv) Wiring: + Remove cover + Clamp wire R (L1) to contact point 1, clamp wire MP (N) to contact point 2. Clamp the grounding wire SL (yellow/green) to the grounding strip. + Remount cover 2. ELECTRICAL CONNECTION OF THE VERTICAL MILLING AND DRILLING UNIT + Remove plug, mount screw=type conduit fitting Clamp wires 1,2 and 3 of the vertical unit motor cable to contact points 3,4 and 5. Clamp grounding wire (yellow/green) to grounding strip. 4+ Mounting the condensor for the vertical milling and_drilling unit one cable is clamped to to contact point 6, the other to contact point 7. Mounting the condensor with Standard and VDE electrical Mounting the condensor with Special Safety electrical version ELECTRICAL CONNECTION OF THE COOLANT PUMP Clamp wire R (L1) and wire Mp (N) to contact points 9 and 10. Clamp the grounding wire SL (yellow-green) to the grounding strip. ELECTRICAL CONNECTION OF THE MACHINE LAMP Clamp wire R (L1) and wire Mp (N) to contact points 11 and 12 Clamp the grounding wire SL (yellow-green) to the grounding strip.Electrical Connection — Three-phase 1, POWER SUPPLY 3. Required cable section: Sx 1,5 mm? Wiring: + Remove cover + Clamp wires R (11), $ (U2) @ (13) and MP(N) to contact points 1,2,3 and 4. Clamp grounding wire SL (yellow/green) to grounding strip. + Remount cover Note: Compare switching symbol with the turning direction of the spindle. If the motor runs in the wrong direction, interchange 2 wires, for example R (51) and § (12). 2. ELECTRICAL CONNECTION OF THE VERTICAL MILLING AND DRILLING UNIT Clamp wires 1,2 and 3 (black) to contact points 5,6 and 7. Clamp the grounding wire SL (yellow/ green) to the grounding strip. check running direction of the vertical unit. If the motor runs in the wrong direction, (see arrow on gear cover), interchange 2 wires, for example wires 1 and 2. 13 ELECTRICAL CONNECTION OF ‘THE COOnANT PUMP Clamp wires R (11), S$ (L2) and T (L3) to contact points 8,9 and Jo. Clamp the grounding wire (yellow/green) to the grounding strip. The coolant pump functions equally in either running direction. ELECTRICAL CONNECTION OF THE MACHINE LAMP ae Clamp wire R (L1) and wire MP (N) to contact points 11 and 12. Clamp the grounding wire SL (yellow/green) to the grounding strip. ER uekueturc Is Ore eM iMan crs Piero cccieusImportant Guidelines for Operation All levers must be switched so that they rest in the bores. Change speeds and feed only when machine is not running. The shearing pin is made of a special alloy; do not use other materials to replace it, when it is broken through overloading or incorrect handling. Do not clean machine with compressed air - dust and chips would damage precision guideways and bearings! After working with coolant, clean and oil the machine. The multi-spline flat belt must be tensioned correctly. Do not hammer the main spindle (high-precision bearings Lubricate according to lubricating instructions. When working with the toolpost grinder, cover all guideways. The swarf could damage the precision guideways. 4Starting the Machine The machine must be connected professionally; voltage and frequency must correspond with motor specifications. Set the required main spindle speed, feed direction and size. The main and emergency-off switch is switched on (does not apply to standard electrical version) « Note: Switch can only be switched~ on when electrical current is present. Switch motor to required revolving direction and speed. 6Controlsa 19 20 241 22 Controls — Lathe Lockable main switch with low-volt lo Cross slide handwheel resp. no-volt release 11 Top slide handwheel Switch for selecting motor speeds and direction of revolutions 12 Handwheel for tailstock ram Levers for selecting spindle speeds 13 Convertible clamping lever for tailstock ram Knobs for selecting feeds resp.pitches 14 Convertible clamping lever for Reversing gear lever tailstock Coupling for lead screw 15 Bolts for setting-over tailstock Half-nut lever 16 Clamping screw for longitudinal slide Feed lever for longitudinal and cross feed 17 Clamping screw for cross slide Longitudinal slide handwheel 18 Hexagon nuts for fixing top slide a the required angle Controls — Vertical Milling and Drilling Unit Handwheel for vertical slide 23 Clamping lever for vertical slide Lever for lowering pinion 24 Levers for switching spindle speeds Adjustable depth stop for pinion 25 Switch for vertical motor Clamping lever for pinionControls Lathe Bed The lathe bed is made of high~ grade cast-iron. ‘The combin- ation of high cheeeks with strong diagonal ribs gives a bed, which has low vibration and rigid qualities. Two high~precision ground Ve2-guideways, one for the carriage and one for the tail- stock assure accurate travel Four bores are provided at the back of the lathe bed for mounting the vertical milling and drilling unit. Power Transmission Drive Motor — Gearbox From motor via multi-spline flat belt to intermediate shaft over sliding gears to main spindle. From main spindle over reversing mechanism over gears in universal quadrant to gear~ box. 18 Headstock The headstock is made of vibration- free, strongly ribbed cast-iron It is tightly fixed to the lathe bed. The main spindle is supported by two highly-precise adjustable taper roller bearings. The high ri- gidity of the main spindle (Ro 48 daN ym) guarantees highly-precise results. All gear wheels in the headstock are made of steel alloy; they are heat treated and scraped. The sloped sliding gears facilitate switching speeds. All gears of main spindle and the reversing mechanism run in an oil bath. The front plate on the headstock indicates lever positions and the corresponding speeds and the feed directions, as well as the turning direction of the main spindle. Switching the Spindle Speeds During the switching operation, the main spindle is slightly turned by hand. Switching the Reversing Gear During the switching operation, the main spindle is slightly turned by hand.Gearbox The housing is made of cast- iron and is fitted to the front of the bed. The large-dimensioned sliding gears are sloped for facilitated switching the feeds and thread pitches. All gears run in an oil bath. Pitches and feeds are set according to the chart on the front of the gearbox. The leadscrew and the feed shaft are positioned to the right of the gearbox. Switching the Feeds and Pitches During the switching operation, the main spindle is slightly turned by hand. ie Desolace ene Eriletaroaaeteu iat Reeka: 0 1 Slipping clutch on the feed shaft (1) the slipping clutch on the feed shaft protects the machine against overload and makes it possikle to turn toa stop in longitu- dinal and cross directions. 2 Coupling on the lezdserew (2) If the coupling sleeve is pulled to the right, the leadscrew is disencaged. The leadscrew is engaged only for thread cutting_and should be disengaged by means of its coupling (2) during normal turning.The apron is fitted to the longitudinal slide. The worm gear and toothed gears are greased. A lock is fitted in the feed lever to prevent an accidental movement from long- itudinal feed to cross feed. Half-nut lever and feed lever are also interlocked, so that only one at a time can be engaged. Engaging the Feeds Only the direction, which is shwon with an arrow-symbol on the feed lever, can be obtained. In order to change to the other feed, the lever has to be, pulled out and turned 180' ing the Longitudinal Feed 1, Pull out feed lever and turn to longitudinal feed (see arrow 20 2. Pull out feed lever and swing upwards Setting the Cross Feed 1, Pull out feed lever and turn to cross feed (see arrow) 2. Pull out feed lever and swing downwards. Couplin: the Half-Nut for Threadcutting By swinging the half-nut lever clockwise, the half-nut engages with the leadscrew. When leadscrew is not moving, the longitudinal slide is slightly moved by means of the handwheel, until the half-nut can be engaged easily.Slides he Longitudinal Slide The longitudinal slide runs on the ground Vee of the bed without play. The optimal ratio of guidance guarantees extreme accuracy and smooth movement. The large-Gimen- 3ioned longitudinal slide handwheel is provided with a scale ring. The longitudinal slide can be slamped with the hexagon screw (1). when precise cross turning is being done, it is recommendable to clamp the longitudinal slide. 2. The Cross Slide The cross slide runs in an adjust- able dovetail guide without play. It can be clamped with a socket head screw (2). The three t-slots serve for mounting the top slide and other tools or accessories (tool-post grinder, dividing head, angle plate, milling table, etc.). The adjustable scale ring (divi- sions 0,025 h metric ma- chines, 0,001" with inch type ma~ chines) on the cross slide enab- les accurate feeding. 21 3. The Top Slide The top slide is mounted to the cross slide with 3 t-nuts and socket head screws. After loosening the 2 hexagon nuts (3), the top slide can be turned to any required angle. The graduated scales enable exact angle positioning. Internal and external tapers in any required angle and up to a length of 100 mm can be machined. The top slide runs in an adjustable dovetail guide without play- The adjustable scale ring (divi- sions 0,025 mm with metric ma~ chines, 0,001" with inch type ma- chines) on the top slide enables accurate feeding. Mounting the Turning Tools 1, Directly with the clamp The distance between top slide and center height is 23 mm (0,905"); for this reason, steel spacers of corresponding size must be placed under the turning tool to set it to exact center height. 2. With the fourway toolpost or the quick-change toolholder The fourway toolpost resp. the quick-change toolholder is moun- ted on the top slide. jp sotes [Be main cutting edge of the tur- ning tool must be exactly at cen~ ter height.The Tailstock The tailstock is set on the reer Vee of the lathe bed ané is made of high-grade vibration-free cast-iron. The tailstock ram is moved vie the handwheel (travel of tailstock ram 90 mm 3,54"). A Craduated scale is engraved into the tailstock ram. Accurate feed is guaranteed by a scale ring on the tail~ stock handwheel Scale graduations on metric ma~ chines 0,025 mm, on inch type machines 0,001". Note: Pailstock ram should always be clamped, exept during drilling work. The inside taper of the tailstock ram (MT 2) serves for receiving centers and drill chuck. By turning back the ram, the center or drill chuck is automatically ejected. The tailstock itself is clamped to the lathe bed with the large and powerful clamping lever. Resetting the Clamping Lever The clagping 1gver can be reset from 60" to 60°, in order to place the lever in the most convenient position for working. Resetting: The clamping lever (1) is turned out so far, until the hexagon screw (2) can be turned in the, slot of the wedge (3).Taper Turning Using the Setting-over the Tailstock Tailstock Set-Over Example: Setting-over the Long and narrow tapers can tailstock to the be machines also with auto- front matic feed, by setting-over the tailstock. The rear screw is loosened. The workpiece must be clamped By turning the front screw eee ceneeeee . (1) clockwise, the tailstock is moved to the front. When the required set-over position is achieved, the rear screw is tightened again. pee ei vey *T With the aid of the line marks (2), the tailstock can again be brought to the required position. Ne Front and rear screw must be tightened against each other. 23Cutting speeds in feet/min. Cutting speeds in m/min. 900 000-| "S00. 2000-+- 400 50-4200. 200150. 200400 04-50 0] —a0- 120-}—30- 604-20. aa-ho. ast. Cutting Speeds ais a2" ay oe ase te ees ee i Workpiece diameter in mm Workpiece diameter in inch 24Approximate values for cutting speed — Cutting angle ~ Lubricant \Valus vai for dry cutting wth: High spead see! tH for cutting spon! v60 (age 6Omin.) Carbon taped tools for euttng seed v240 tage 240min.) Side angle =A52, point angle € = 90°, angina ineinatinn An 0.8, for tight aoy end plastic 2 = 5. ‘cutting speed 10°, “Thase vues old good for cuts up to 8mm deep, over Sm the cutting speed should be reduced by 10-208, 1) 55~ high span set 11 G1 tioped tools €= Curtingemutsion P= paratin Wickes tense [4 | curing ate [Cootant al Lubeicae| maria seanath , | Too!| cleararefton in koma oy |e Roughing | Finishing | _fas} x Suet 5134, wes ss | a | 14 co] 45] 38] © fee 5137, 842 8, | 5 | 10 | 200] 236| 200] 170 aan cael seso.seeo | 0.70 1s, | 5 | 10 | 24o| 205] 175] 145| © [eore 77 Iz] 2] Te 2 ieee s_| 10 | 200] 170| 132| 10s] _€ _leore a ye on ne s_| 6 | ta} to] as] | © lov a} 0 fT] 1 Alayedset | 85-100 s_| 6 | wo] re] 95| 75] © leore Tinea CON po 1] T] suai crones| "140 15, | 5 | 6 | o5| 75] oo] sol _e leore ther alloyed 5 ama seats r40190 |s, | 5 | 5 | col «| sa] x2] © leorp sas r Tol stat rso.190 |g [5 | 6 | so| 4o| 32| 27| © _|cotmoitore arco [SS[ eo are} Benet c120.6125 | 209..250 [Hy | 5 105] 90| 75] 63] ary ort ory Caper Tarde eo 125 a5] 50 7 alloys Binet go120 |c, | 5 | 5 | 600] sa0| a50| a00| drveortfoy : sao Bry sa] aa P cones s, |s | 6 a0 236| 200| eet fay Taare Sere} 30 aba | 300] 200] 118 | Ear FYE or suminium G, }12 | a0 | 1320 }1120 | 950] 880] soap spi |soap si aaa Sie aia ar] Ba attoys (nr38s0 cs, [12 | 19 | 224| 190| 160] 40] e fous Mares SEF TOO] BRT | BO] 780 | ay ar av oF wi ailoys* &, | 5 | 6 | 1900 |1500 |r250 |1060 | ith nonfnon-comsunible combust fo inl oi! hard rubber {12 | 10 | 300 | 260 | 250 | 224| dey ley Bakelite. Now: seta text Perino G, [12 | 14 | 200] 22] 170] 132] ay fay | ord laste i + Do not use with water or water mixtures {DANGER OF FIREW 25% Lubrication Headstock (remove cover for oil change Oil sight glass on headstock Drain plug on headstock Filling screw in gearbox Oil sight glass on gearbox Drain plug on gearbox Grease nipple for carriage Grease nipple for tailstock spindle9 Grease nipple on cross slide 16 Leadscrew jo Grease nipple for leadscrew support 17 Toothed rack 11 Grease nipples for change gear bolts 18 Oil filling and draining screw on the vertical unit 19 Oil sight glass on the vertical unit 20 Pinion of the vertical unit 21 Vertical spindle 22 Vertical column 12 Top slide guideway 13. Cross slide guideway 14 Tailstock ram 15 Bed guideways az Lubrication table machine pact Tubrication 70s. | control Pos. | materia | type of tubrication | quantity | Frequency ‘| Spindlestock 1 oil oi1 bath ap.0,4 7 approx. 500 hours Gear box a on ap.0,4 2 carriage 7 = Tallecock spindle 8 5 Top alide apindle 3 = crease creasegun approx. 24 hours Leadesrew io = Change gear bolt i = Top slide 2 = ‘Gross slide 3 = Several times a day, Tailstock ram 18 = sn O41 can ceeeesnsssereiae 5 = 16 = Toothed rack a7 = crease approx, 24 hours Vertical unit 18 9 oan oil bath 9.0/5 1 | approx. 300 hows Pinton 20 = Spindle 2 = on ost can Weekty ‘olan 22 .Recommendations for Lubrication ‘The machine should be servicea according to the lubrication plan. The temperature referred to with the viscosity data is 40°C (100° F - ISO STANDARD) . . HEADSTOCK, GEAR BOX Resistant to aging, non-foaming, corrosion, preventive with good viscosity temperature coefficient. With normal temperature conditions oil with viscosity 46 mm2/sec. (cst) at 40°C (100°F) . For example CASTROL HYSPIN AWS 46 For_extreme temperatures: a) under 0°C, viscosity 34 mm2/sec. (cSt) at 40°C (100°F) For example CASTROL HYSPIN AWS 32 b) Over 90°C, oil with viscosity 68 mm2/sec. (cSt) at 40°C (100° F). For example CASTROL HYSPIN AWS 68 2. GUIDEWAYS Pressure absorbing, Cozrosion-protective oil with Stick-Slip reducing qualities. 73 mn2/sec. (cSt) at 40°C (100°F) For example CASTROL MAGNA DD 68 this 011 corresponds with the Cincinnati-Milling Specifications P47. 28 3. GREASING POINTS Lithium-reinforced multi-purpose grease with high dropping point. Penetration approx. 285 (consistency Nr.2) For example CASTROL SPHESROL EPL 2 This grease has an operating tem- perature from -30°C to +110°C. COOLANT. For close tolerance work with high surface quality, combined with long tool use, we recommend emul~ sions such as CASTROL CLEAREDGE EP Recommended mixing ratio 1:30. The transparent microemulsion with EP-additives is extremely resis- tant to attack by microorganisms. It offers good corrosion resis tance, does not stick, does not offend the skin. The smell of this coolant is pleasant. SPECIAL GUIDELINE The required lubricating oils and greases are available from pro- fessional sources (representatives of 041 companies). These recommended oils, resp. greases are basically different from those available at gas stati- ons.Adjustments ADJUSTMENT OF THE MAIN SPINDLE BEARINGS The precision main spindle bearings are correctly ad- justed and preloaded at the factory, so that the main spindle runs without play. I£ play becomes evident after considerable use, the bearing must be adjusted Adjustment of the Bearings: Loosen set screw (1), tighten slotted clamping nut (2) clockwise with a "C" spanner. Then re-tighten the set screw again to secure nut. Checking the Correct Adjustment Disengage sliding gears in the headstock. Set reversing gear into neutral (0) position. If the chuck is turned strongly by hand, then the spindle should make one more free revolution. Note: Excessive preloading of the bearings will cause unnecessary heating-up and wear of the bearings. 29 2. COMPENSATING PLAY OF THE CROSS SLIDE SPINDLES IN THE CROSS SLIDE NUT Necessary when cross slide does not move when the hand- wheel is turned a certain angle. Adjustment: Dismount the top slide and adjust set screw until back- lash is compensated. Check The cross slide should run smoothly. Excessive adjustment causes unnecessary wear of the cross slide nut. 3. COMPENSATING PLAY OF THE TOP SLIDE SPINDLE IN THE TOP SLIDE NUT cross and top slides are equipped with gibs. adjustment of play-free guidance is done with the set-screws (1), which press onto the gib via the pressure pins.2 Adjustment Dismount the top slide and adjust set screw (1) on the bottom side of the top slide, until backlash is eliminated. Checking: The top slide should run smoothly. Excessive adjustment causes unnecessary wear of the top slide nut. 4. ADJUSTMENT OF THE DOVETAIL GUIDEWAYS OF CROSS AND TOP SLIDES Cross and top slides are equipped with gibs. Adjust- meat of play-free guidance is done with the set screws(i),which press onto the gib via the pressure pins. The hexagon nuts (2) are for securing the set screws (coun- tering). 30 Adjustment: Loosen hexagon nuts and adjust set screws until slides run without play, but smoothly. When coun- tering hexagon nuts, hold the set screw with a screwdriver in the adjusted position, to prevent further turning of the set screw. Further turning would clamp the slides. 5. COMPENSATING OF TOO MUCH PLAY BETWEEN HALP-NOTS AND LEADSCREW 3. 20 Unscrew the socket head screw (1) 2 or 3 turns. En- gage the half-nut completely with leadscrew by means of half-nut lever. Now turn in the socket head screw until the other part - of the half-nut is touched, but not moved. Now make a further half turn of the socket head screw and » the correct play will exist between half-nut and lead- screw. Note: This correct play does aot influence the precision of cut threads. Without this play, there is the danger of rubbing and unnecessary wear.6. ADJUSTMENT OF HALF-NUT GUIDANDE Tf the half-nut lever turns downwards by itself during thread cutting, the guidance must be adjusted. Adjustment: Loosen hexagon head screws (2), adjust set secrew (3). Re-tighten hexagon head screws again. Checking: The operation of the half- nut lever must be smooth. SeanE 7. ADJUSTING AXIAL PLAY Oi THE LEADSCREW Necessary when the leadscrew can be moved axially by hand. Adjustment: Adjust the sccuring nut (1) until the axial play is not more than 0,05 mu (0,002"). For holding the leadscrew when adjusting, engage the half-nut. 31 Checking Tf you cannot turn the lead~ screw by hand, the securing nut is too tight. 8. REPLACING THE SHEARING PIN (1) ON THE LEADSCREW If the shearing pin breaks through overloading or in- correct handling of the machine, replace it only with an original shearing pin. Procedure: Remove the rest of the shear~ ing pin with a punch; insert a new one.Accessories — Lathe Lathe chuck, setf-centering 40 mm 5") dia, 2x3 ws according fo DIN 55021 Ord. No. VV 336 Set of three soft bianc jaws Ord. No. T1D 013 Lathe chuck, self-centering 140 mm 55") Gia, 2x4 aws according fo DIN 85021 Ord. No. V3V 338 Set of four soft banc jaws Ord. No. T1D 014 Revolving center MT 2 | Ord. No. 732 000 8 | Fourway toolpost frtools up to max. 12 mm height Ord. No. 584 190 Set of change gears Torcuting additonal threads Ord, No. 584 200 Longitudinal stop Ord. No. 584 030 ee Independent chuck agRE TE aa wa in duaty etl ad rover Sable ews: according o Bineboot Ord. No. P3E 334 Clamping plate Binnen Ord. No. 584.080, Quick-change toolpost ‘wilh footholders (1 standard tool- holder for tools of square section, 1 paning-offtoolnolder with blade} and 2 operating keys Ord. No. 844 000 Standard toolholder Tor quick-change tooipost, for tools with square section Ord. No. $11 000 Boring bar holder for quick-change tooipost, with prism for fools with round Section Ord. No. 811 200 Parting-off holder with blade far quick-change toolpost Ord, No. 511 400 Parting-off blade only Ord. No. 514 600 jaw drill chuck 13 im capacity Ord. No. 250.000 Fixed steady Ord. No. 584 420 (Ord. No. 584 240 Lateral stop Ord. No. 848 000 Morse taper arbor MT 2 Ord, No. 251 000 Traveling stead {prurerigies or 4—60 mm dla (eemachne a0 mn Ord. No. 584 320 dito tor machine 195m Ord. No, 584 230 ‘Thread dial indicator Tor mounting on the side Ord, No. 584210‘Toolpost grinder (185 Wat) Collet holder Quick act, collet chuck oes Mae BINSBO2T, pe L20 Sipe SSF 20 nomewre seamen Setot9 grinding wheels Peo Ord. No. 584 040 01d. No. 584 070 Seriogiem gate oer BEB SNe SE ve Set of 37 collets ype L20, 220 mm, Insteps c10.5 mm Ord. No. 713 600 Set of 23 coll ‘ype L 20, a=" in steps Ot Na Ord. No. 713 650 Individual collets Ord. No. 713 6..* + Pease ste sizes when oceing Facing toolholder 0 be used with indexable insert Ord. No. 518-200 Ord. No. 585 210 Set of 8 rubbertiex colleis 4-20 mm, in steps of 2mm. Ord. No. 445 100 individual rubbertlex collets 4=20 mm, steps 2 mm (Ord, No. 445 1 Ordering example: 445101, 445 102, dia (am) [4-6 [68]. ._[18-20 (Ord. No. [or [oa [| 08 Tools — Lathe ‘Tuming toolholder right fo be used with Indexable insert (Ord, No. 513 400 Ord. No. 585 240 Safety lathe dog Ord. No. 585 120 Set of 4 levelling elements Ord. No. 585 110 Set of 10 carbide tips Indexabie inserts right Ord. No. 513 400 Boring toatholder tobe used with indexable insert (rd, No, 585 260 Ord. No. 585 220 Roughing tootholder right tobe used with indexable insert Ord. No. 518-400, Ord. No. 585 250 Set of 10 carbide tips indexable iseris for boring toolholder Ord. No. 585 260 ‘Turning toolholder left io be used with indexable insert (Ord. No. 513 200 Ord. No. 585 230 Set of 10 carbide tips indexable inserts lef Ofd. No. 513 200 Box of 6 ground SS Too! bits (Ord. No. 885 200Accessories — Vertical Milling and Drilling Unit Collet holder MT2 ‘With Key for double conical collets £25, Ord, No. 721 000 412 double conical caleis E 25 417 double conical colats E 25 iemipe.w anes 2mm wap! om ineh ype nes SSS Wrst of 1/32" Ord. No. 242 100 (Ord, No, 242 145 25 double conical collets € 25 Z.double conical calles E25 Fameypainauee2=Tamm,nstepeof0S mn frentypa mazes 78112" senso 118 (rd. No. 242 101 Ord, No, 242 150 Individual double conical collet E 25 ‘Peat tae aza wen ocering OT. NO. 242 1." jaw drill chuck 5=13 mm capacity (Ord. No. 250 000 Morse taper arbor MP2, for dri. chuck (Ord. No. 251 000 Shell end mill arbor with MT 2, fo suit 16 rn cutter bore dia Machine vice ‘eth os 170 mm, ma pening | 10 mm, can also be sounted witout swivel base Ord. No. 763 000 Ord. No. 761 310 se Lathe chuck, self-centering 40mm 6.5") da, 2x3 jaws, according fo DIN 58021 Ord, No. VV 336 Setof three sof blanc jaws Ord. No. TID 013 Spanner ‘Swivel base Tor shell end mil arbor foruse aith machine vice Ord. No. 763 900 Ord. No. 761 320 Lathe chuck, self-centering 740 mm (5,5") dia, 2x 4 [as according fo DIN 55021 Ord. No. V3V 338 Set of four soft blanc jaws (Ord. No. T1D 014 Set of 4 spacing collars, ‘ardened and ground, for shell fendmill arbor, 4mm, 8 mim, 8mm and 12mm Ord. No. 763 100 ‘Stepped clamping shoe Complete with clamping bol sipping capacity 1060 mm Ord. No. 465 100 ‘Support backplate Born da, for mtrtng lathe chuck pero side, ming odie or angle plate Ord. No. 584 250 ‘Angle plate {iding ec, swivel base, stepped camping shoos, irachine vie aid ithe chuck Tan be mounted onto the ange plat by using the suppor backplate Ord, No. 760.020 Dividing head with circular table for direct and Ingiect dividing, circular table 150 mm cia, Ord. No. 745 000 Boring and facing head Fy cus in box wit Tootolcer, culler 66x40 mm and servicing toois Ord. No. 525 330 Milling table {an be mouried on cross slide for fixing angle plate or for lamp roe suaced wore pieees (400X280 mm Ord. No. 565 350 Ord. No. 584 170 Adaptor plate 125 mm dia. for mounting the lathe chuck fo the divicing headoe Tools — Vertical Milling and Drilling Unit sss 25 twist drills, HSS inbox, DIN 381-13 mm, in steps of 0,5 mm Ord. No. 764 000 Heavy-duty taper shank ‘end mil far roughing cut, shank MT 2, drawn screw thread M10, dia of cutier 15mm HSS. Ord, No. 764 100 ssl Heavy-duty straight shank end mill, for roughing cut, ¢yindrical shank, dia. of cutter 8 mm, HSS ‘Ord. No. 764 200 Heavy duty shell end mill whith spiral for roughing! finishing, ore 16 mm, length 20 mm, da. of cutter 40 mm, HSS (GIN 641, 7 teeth) Ord. No. 764 410 End mill cutter, HSS with eylindrical shank 3mm Ord. No. 764 301 4mm Ord. No. 764 302 BSmm Ord. No. 764 303, Emm Ord. No. 764 304 so Dovetail mill, HSS vaih eyindrical shank 12 mm dia. 60°, 16 mm dia Ord. No. 764 400 lot cutter, HSS ‘win oylinarical shank, dia. 10 mm {or T-siot 12,5x6 mm ‘Ord. No. 764 510 dita, for T-slots 16x8 mm (Ord, No. 764 520 Staggered tooth side mill, HSS bore'16 mm, width S mm, de ofeutter 5 mm, HSS Ord. No. 764 900 ditto, width 8 mm, dia. of cutter 5a mm, HSS Ord. No, 764 910 | Circular saw blade fine tooth, bore 16 mm, width 0,5 mm, dia. 60 mm Ord. No. 123 100 S.gear mills Felieved, for 20° pressure angle hore 16mm, da.ofcutters40mm, HSS, module 0.5, mill no. 1-8 Ord. No. 764 600 8 gear mills ieleved, for 20° pressure angle, bore 16 mm, cia. ofcutters, 0 mm, HSS module 1, Individual gear mill _ individual gear mill Ordering Example: .. 764 601, milino. 1-8 mooleOS modileT ae 70480 Ord. No. 764 700 Ord. No. 764 6. Ord. No. 764 8. Soeaols ressure angle Teeth: (2-13 [14-16 | 17-20 | 21-25) Soe tammda crower” Individual gear mij «(Order oz] ot Toe os oH} 50mm, HSS, module 1,26, mil Module 7 ‘Teeth: [26-36 | 95—64 [65-134 | 195-= fto.1-8 Ord. No. 764800 Ord. No. 764 7. OrderNoz] 05 | 06 | o7 | 08