Page 1: Table Of Contents
Table of Contents Introduction Section 4 : Maintenance Foreword Schedule Contact Info Cleaning Functional Overview Lubrication Cutting Fluid System Safety Instructions Machine Storage Lathe Safety Section 5 : Service Section 1 : Controls & Components Backlash Adjustment Identiﬁ cation Leadscrew End Play Adjustment Control Panel Gib Adjustment Headstock Controls...
Page 2: Introduction
Introduction Foreword Functional Overview We are proud to offer the Model RML-1640V High The Model RML-1640V High Precision Electrical Precision EVS Lathe. This machine is part of a Variable Speed Lathe that has a pressurized headstock growing SUN MASTER family of ﬁ ne metalworking oiling system.
Page 3: Safety Instructions
Safety Instructions ATTENTION It is essential to read this operation manual and understand the program instructions and maintenance instructions before operating the machine. This operation manual should be attached to the machine at all time where it is readily available to the operator for reference.
Page 4: Lathe Safety
Lathe Safety 1. Clearing Chips : Metal chips can easily cut 7. Speed Rates : Operating the lathe at the wrong bare skin—even through a piece of cloth. Avoid speed can cause nearby parts to break or the clearing chips by hand or with a rag. Use a brush workpiece to come loose, which will result in or vacuum to clear metal chips.
Page 5: Section 1 : Controls & Components
Section 1 : Controls & Components Identiﬁ cation Figure 1. The RML-1460 EVS Lathe. Headstock 11. Gearbox Control Panel 12. Removable Chip Drawer D1-6 Camlock MT#6 Spindle 13. Apron Steady Rest 14. Brake Pedal 4-Position Tool Holder 15. Thread Dial Work Lamp 16.
Page 6: Control Panel
Control Panel Headstock Controls Figure 2. Control Panel. 1. CSS ON / OFF Switch : Turns the constant surface speed feature ON or OFF. 2. Tachometer Display : Indicates what RPM the spindle is currently rotating at. 3. Spindle Speed Dial : Changes the spindle speed to user-deﬁ...
Page 7: Carriage Controls
Carriage Controls Tailstock Controls Figure 6. Tailstock Controls. 1. Graduated scale : Indicates quill movement in increments of 0.001" or 0.02mm. 2. Tailstock Lock Lever : Secures the tailstock in place along the bedway. Figure 5. Carriage Controls. 3. Quill Lock : Locks the quill in position. 1.
Page 8: Section 2 : Setup
Section 2 : Setup Physical Environment The physical environment where your machine is operated is important for safe operation and longevity of parts. For best results, operate this machine in a dry environment that is free from excessive moisture, hazardous ﬂ...
Page 9: Leveling
7. Moving the machine with a forklift. a. Make sure that the minimum forklift capacity Half Nut Lever is more than 2 tons for security. Carriage Handwheel b. Forklift work should be cooperatively done Lock Bolt by two persons, that is an operator and watchman, not to damage projecting on the machine perimeter.
Page 10: Test Run
To level the machine, use a precision level to make 6. Move the headstock range lever ( Figure 16 ) to sure the bedways are level from side-to-side and the left so the headstock is in low range ( 20-400 from front-to-back.
Page 11: Spindle Break-In
10. Using a 10mm hex wrench, loosen the carriage 14. Make sure that all bystanders are out of the way, lock ( Figure 20 ) so the carriage is free to slide. tools are cleared away, and the chuck key is removed from the chuck.
Page 12 4. Move the headstock range lever to low range. 7. Turn the lathe ON, and let it run for ten minutes in each speed of 20, 200, and 400 RPM, using the 5. Move the feed direction forward / reverse lever ( dial to adjust the speed.
Page 13: Section 3 : Operation
Section 3 : Operation CSS System This lathe is equipped with a CSS (Constant Surface Speed) system (Figure 27) that gives consistent ﬁ nishes between surfaces with different diameters. Spindle RPM Readout CSS Switch Spindle Speed dial Figure 28. Camlock loosened with the cam line aligned with the datum line.
Page 14: Jaw Chuck
8. Lock the other cams in a crisscross or star To change the jaw : pattern so the chuck is drawn up evenly on all 1. Disconnect Lathe from POWER ! sides without any chance of misalignment. 2. Place a piece of wood over the ways to protect 9.
Page 15: Tailstock
It can also be used to drill or bore holes in the center of a part or cut shallow tapers by using the offset adjustment. Tailstock Lock Lever Tailstock Lock Lever Quill Handwheel Figure 34. Tailstock and quill lock handles in Figure 33.
Page 16: Centers
Live Centers 2. When the offset is achieved, snug the jack screws so the tailstock position is locked. A live center has bearings that allow the center tip and the workpiece to rotate together, and can be installed in the spindle and the tailstock quill for higher speeds, Left Side but with a slight bit of accuracy loss.
Page 17: Steady Rest
Steady Rest Follow Rest The steady rest supports long shafts and can be The follow rest mounts to the saddle with two cap mounted anywhere along the length of the bed. screws (Figure 40). It is used on long, slender parts to prevent workpiece ﬂ...
Page 18: 4-Way Tool Post
4-Way Tool Post • Make a facing cut on a piece of round bar stock. If the tool is above/below the spindle center line, a nub will be left in the center of the workpiece. The four-way tool post is mounted on top of the Adjust the height of the workpiece, then repeat compound slide, and allows a maximum of four tools the facing cut to check the adjustment.
Page 19: Manual Feed
Manual Feed Determining Spindle Speed Many variables affect the optimum spindle speed You can manually move the cutting tool around to use for any given operations, but the two most the lathe for facing or turning operations using the important are the recommended cutting speed for the handwheels shown in Figure 45 and described below.
Page 20: Power Feed
3. Adjust the spindle speed range lever to the range that covers your calculated spindle speed. 4. Turn the spindle ON and slowly turn the variable speed dial to carefully adjust the spindle speed to your calculated spindle speed. Power Feed On this machine, both the carriage and cross slide have power feed capability.
Page 21: Positioning Gearbox Levers
Understanding Thread & Feed Rate Chart Figure 45 shows the conﬁ gurations of gearbox levers that are required to set the available feed rates. This same chart can also be found on the machine. Figure 50. Thread and feed rate chart. Positioning Gearbox Levers To cut a particular thread or establish a particular feed...
Page 22: End Gear Setup
End Gear Setup Normal Position ( Metric ) The 28T end gear is installed in the top position, the 55T/54T end gears in the middle position, and the The gearbox drive gear on this lathe can be 64T/22T end gear in the bottom position, as shown conﬁ...
Page 23: Half Nut Lever
Using Thread Dial and Chart (Metric) Find the length of each thread that you want to cut Feed Control in the left column (see Figure 55), then reference Lever the dial number to the right of it. The dial numbers indicate when to engage the half nut for a speciﬁ...
Page 24 Using Thread Dial and Chart ( Inch ) Length of each thread 4, 5, 9 Select position 1, 3 on the thread dial and use the 18T Find the TPI ( threads per inch ) that you want to cut gear on the buttom of thread dial for threading length in the left column (see Figure 60), then reference of each thread 4, 5, 9.
Page 25: Cutting Fluid System
Cutting Fluid System Odd Numbered TPI Use any of the numbered lines on the thread dial for threading the TPI shown in Figure 63. The cutting ﬂ uid system delivers cutting ﬂ uid through a positionable nozzle and is controlled by the control panel cutting ﬂ...
Page 26: Section 4 : Maintenance
Section 4 : Maintenance Schedule • Remove electrical box air ﬁ lter and clean with compressed air or a vacuum. Each operator of this machine is responsible for ensuring proper care of the equipment. We strongly Annually ( or Semi-Annually with Hard Use ) recommend all operators make a habit of following •...
Page 27 Verifying Oil Pump Operation If the oil pump ever stops working, the spindle bearings Oil Fill Spout and headstock gears will stop being lubricated, which can quickly result in major damage. Therefore, it is critical to regularly monitor the oil ﬂ ow while operating the lathe.
Page 28 Gearbox Oil Fill Plug Suction Screen Gearbox Oil Drain Plug Figure 71. Suction screen removal. Figure 73. Location of gearbox ﬁ ll and drain 9. Clean the suction screen thoroughly with mineral plugs. spirits and compressed air. Apron 10. Reinstall the suction screen. Checking &...
Page 29: Lead Screw
Lead Screw & Feedrod Bearings Unpainted & Machined Surfaces Checking & Adding Oil Besides the ways and leadscrew, all other unpainted To check the oil level, remove the ﬁ ll plug and look and machined surfaces should be wiped down inside the reservoir (Figure 76).
Page 30: Cleaning Electrical Box Filter
Cleaning Electrical Box Filter The door of the electrical box contains an air ﬁ lter ( Figure 80 ) to prevent dust from entering the box as the cooling fan pulls in cool air to reduce heat. The air ﬁ lter should be cleaned on a monthly basis to ensure proper air circulation in the electrical box.
Page 31: Cutting Fluid System
Cutting Fluid System Adding Fluid 1. Disconnect Lathe from POWER ! The cutting ﬂ uid system consists of a ﬂ uid tank, pump, and ﬂ exible nozzle. The pump pulls ﬂ uid from 2. Remove the vented cover and slide the tank out, the tank and sends it to the valve, which controls the as shown in Figure 83.
Page 32: Machine Storage
5. Cover and place the machine in a dry area that is out of direct sunlight and away from hazardous Fluid Hose fumes, paint, solvents, or gas. Fumes and sunlight can bleach or discolor paint and make plastic guards cloudy. 6.
Page 33: Section 5 : Service
Section 5 : Service Backlash Adjustment Compound Leadscrew Cap Screw Backlash is adjusted by tightening the set screws shown in Figure 85. When these screws are adjusted against the leadscrew nut, they offset part of the half nut to remove play between the nut and leadscrew. Set Screw If you end up adjusting the half nut too tight, loosen the set screws, tap the compound a few times with a...
Page 34: Gib Adjustment
Gib Adjustment The goal of adjusting the cross slide, tailstock, saddle, and compound gib screws is to remove sloppiness in the ways without over-adjusting them to the point Left Gib Screw where the slides become stiff and difﬁ cult to move. In general, loose gibs cause poor ﬁ...
Page 35: Feedrod Clutch Adjustment
The half nut is correctly adjusted when it has a slight 4. Insert the hex wrench into the collar adjustment drag while opening and closing. hole shown in Figure 95, and use the wrench to rotate the clutch collar. 5. The movement should not be too stiff or too sloppy.
Page 36: Brake & Switch
Motor Mount Bolts Pulley Move Pedal Stop Left or Right Deﬂ ection Move Brake Band to the to Adjust Foot Pedal Height Right to Adjust Brake Cap Screw Figure 97. V-belt adjustment. Figure99. Brake linkage adjustments. 4. Firmly tighten the hex nuts (loosened in the 5.
Page 37: Leadscrew Shear Pin Replacement
11. Push the pedal lever down to verify that the cam lobe pushes the kill switch plunger in. Rear Position 12. When pushed in, you should hear the switch click. 13. Reinstall the cover, test the brake operation. Leadscrew Shear Pin Replacement To replace the shear pin : 1.
Page 38: Gap Removal & Installation
11. Using retaining ring pliers, return the retaining 2. Remove the two cap screws from the ends of the ring to its groove, and position the retaining ring ways. ears over the shear pin head, to prevent the shear pin from falling out—if the shroud washer rotates 3.