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Manual on the date of issuance and listed herein; On the other hand, the machine may also be subject to important technical changes in the future, without the manual being updated. Therefore, contact FERVI for information about modifications that may have been implemented. REV. 1...
MACHINES AND ACCESSORIES INDEX GENERAL INFORMATION................5 GENERAL SAFETY WARNINGS ..............7 General safety rules for machine equipment..............7 Safety rules for electrical machine equipment ..............9 Technical Assistance .....................9 Other provisions ......................9 TECHNICAL SPECIFICATIONS ..............10 DESCRIPTION OF THE MACHINE ............. 11 Intended use and field of application ................
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Adjusting the slack of the gears ................. 56 REPLACEMENT PARTS................57 12.1 ACCESSORIES SUPPLIED..................80 DISPOSAL OF PARTS AND MATERIALS ..........81 TROUBLESHOOTING ................82 ELECTRIC CIRCUIT ................83 15.1 Art. T999/400V......................83 15.2 Art. T999/230V......................84 Page 4 of 84 www.EngineeringBooksPDF.com...
This manual is designed to provide the knowledge required for the use and maintenance of the Gear head lathe (Art. T999/230V – T999/230V3A – T999/400V T999/400V3A) and to provide the operator assigned to the device with a sense of responsibility and knowledge of its possibilities and limitations.
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MACHINES AND ACCESSORIES The Gear head lathe has been designed and built with mechanical guards and safety devices designed to protect the operator/user from possible injury. It is strictly forbidden to modify or remove guards, safety devices and caution labels. If you do so temporarily (for example, for the purposes of cleaning or repair), make sure that no one can use the machine.
MACHINES AND ACCESSORIES 2 GENERAL SAFETY WARNINGS 2.1 General safety rules for machine equipment Follow the instructions contained herein, in addition to the general precautions to be observed while working. Even if the operator is already familiar with the use of manually operated lathes, it is necessary to: In particular: ...
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MACHINES AND ACCESSORIES 8. Do not perform tasks on the machine other than those for which it was designed. Only use the machine in the manner in which it was intended, as described in this instruction manual. 9. Work without disturbances. 10.
3. The power plug must be a grounded tripolar type plug for T999/400V and a grounded bipolar plug for T999/230V. Any extension cords must be of equal or greater length than the power cord on the machine.
MACHINES AND ACCESSORIES 3 TECHNICAL SPECIFICATIONS Description (unit of measurement) T999/230V T999/400V Centres distance (mm) 1000 Spindle hole diameter (mm) Maximum swing over the bed (mm) Maximum swing over the cross slide (mm) Turning diameter over cavity (mm) Spindle diameter (3 + 3 self centring) (mm)
ACCESSORIES 4 DESCRIPTION OF THE MACHINE The Gear head lathe (Art. T999/230V e T999/400V) is a machine tool, with a horizontal axis, for the machining of metallic materials by means of cold chip removal. The cutting motion is given by the motion of the workpiece, rotating on its own axis, and the feed motion of the tool.
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MACHINES AND ACCESSORIES The lathe is equipped with a support base and must be installed and used on flat surfaces, with ergonomic features and adequate resistance. The Lathe can operate in closed work environments (production halls, warehouses, etc.), i.e. protected from the weather and where there is no danger of fire or explosion. The operating temperature range is -20 to +50°C.
MACHINES AND ACCESSORIES 4.2 Description of the main parts Figure 2 – Main parts of the gear head lathe (Art. T999/230V and T999/400V). Brake Protective device Tailstock handwheel Carriage handwheel Halogen lamp Support bars Workbench Turret Lead screw Speed switches...
MACHINES AND ACCESSORIES 4.2.1 Supporting table The supporting table (ref. 2 in figure 2 ) is made of cast iron; the casting has been stabilized to avoid twisting and/or deformation due to the internal stresses in the material. In the upper part there are prismatic guides that ensure the movement and alignment of the drive head with the carriage and the moving head (tailstock).
MACHINES AND ACCESSORIES 4.2.4 Feed speed adjustment panel The panel for the adjustment of the spindle rotation speed (see figure 5), is positioned at the left part of the machine, under the spindle speed adjustment panel. The lathe is provided with gears that can guarantee the considerable availability of feeds and threads (metric and inch).
MACHINES AND ACCESSORIES 4.2.7 Steady rest In the operations of drilling, boring and facing, the tailstock can not be used to secure the work piece. On the other hand, if the pieces are long and heavy, it is not enough to use only a self-centring spindle, but you must attach one end of the work piece using a tool called a steady rest (see figure They are supplied with two rests: steady rest and follow rest Figure 8 –...
MACHINES AND ACCESSORIES 4.2.10 Rotation reverse lever Lever for reversing the rotation direction of the electric motor. The lever is located to the right of the tool holder carriage. Figure 10 – Reverse lever. 4.3 Identification plate On the machine, and in particular on the feed speed change gearbox, there is the following identification plate (see Figure 11):...
MACHINES AND ACCESSORIES 4.4 Pictograms and plates AUTION AND WARNING PICTOGRAMS The following pictogram has been applied to the side of the electrical panel: Hazard / warning plate. Prohibitive warning for carrying out work on live equipment. Hazard plate. ...
MACHINES AND ACCESSORIES 5 MACHINE SAFETY DEVICES 5.1 Electrical safety devices The electrical circuit of the lathe is equipped with a rotary main switch with a safety key (see chapter 9.1 of this manual). This prevents the danger of unwanted and/or accidental starts of the machine, since the switch can only be activated through a voluntary action suitable for the given purpose and if a suitable key is available.
MACHINES AND ACCESSORIES 5.2 Mechanical Safety Devices Protective screens The screens and guards have the role of protecting the operator by preventing coolant, chips, splinters, tool fragments or even the workpiece, which may detach, from being projected towards the face or torso. The screens are fixed or mobile (see Figure 13).
MACHINES AND ACCESSORIES 5.3 Personal Protective Equipment (PPE) Use of PPE ALWAYS use appropriate personal protective equipment (PPE) such as (see Figure 14): Gloves; Goggles or face shields; Overalls or aprons; Safety shoes. PROTECTIVE PROTECT YOUR PROTECTIVE PROTECTIVE PROTECTIVE...
MACHINES AND ACCESSORIES 6 FORBIDDEN USES AND HAZARDS The modes of use specified in this manual as incorrect, should never be permitted, under any circumstances. Using the machine for turning non-ferrous materials, for unauthorised manoeuvres, its misuse and lack of maintenance can result in serious danger to the safety of the staff, especially the operator, as well as affecting the functionality and the intrinsic safety of the machine itself.
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MACHINES AND ACCESSORIES Using the machine in a dark place. Allowing untrained personnel to use the machine. Operating this machine without being psychophysically fit; Allowing untrained and unqualified personnel to carry out maintenance, and without complying with the procedures specified in this manual. ...
MACHINES AND ACCESSORIES 7 LIFTING, TRANSPORTATION AND STORAGE IN WAREHOUSE 7.1 Lifting To lift the Lathe, proceed as follows: 1. To achieve perfect balance, move the tailstock all the way to the end on the right side of the table and securely fix it with the locking lever; 2.
MACHINES AND ACCESSORIES 8 ASSEMBLY AND COMMISSIONING 8.1 Identification of the installation site To install the machine, identify an area that is well lit, away from wet areas and has no sources of vibration nearby. The lathe must be located so that adequate space is available for the operator, so you can use it to its full potential, and safely adjust, maintain and clean the machine.
MACHINES AND ACCESSORIES 8.3 Levelling the machine For this operation, it is recommended to use a precision spirit level (0.001 mm). 8.3.1 Preliminary phase The preliminary phase serves to eliminate the presence of torsions in the lathe table. Proceed to reset the head by adjusting the relative screws and then locking the tailstock with the relative adjustment screws moving the reference mark to zero.
MACHINES AND ACCESSORIES 8.4.3 Open circuit test Manually rotate the hand wheels on the carriage's tool carrier slides and tailstock quills to verify that these move freely and without friction. Start the machine by turning the main switch to the position I and the activation lever to reverse the rotation of the spindle (see Figure 16) and make sure that the electric motor and...
MACHINES AND ACCESSORIES 9 DESCRIPTION OF CONTROLS 9.1 Control buttons 9.1.1 Main switch The main switch with safety key is located on the left side of the electric panel, and it is useful to prevent unauthorised use of the machine. To power the machine (see Figure 16), in fact, it is necessary to:...
MACHINES AND ACCESSORIES 9.1.3 Emergency button Additionally on the electric panel there is a emergency stop switch: To stop the machine, in cases of emergency, press the red mushroom shaped button. When it is pushed, the motion of the electric motor and other rotating parts is interrupted. Before you begin work, always make sure that the mushroom button is raised.
MACHINES AND ACCESSORIES 9.2.2 Automatic feed speed adjustment knobs Figure 19 - Feed adjustment knobs. The panel for automatic feed speed adjustment (see Figure 19), is positioned at the left part of the machine, under the spindle rotation speed adjustment panel. The different speeds are selected via 4 knob switches which control the gear speed change (ref.
MACHINES AND ACCESSORIES 9.2.3 Adjustment knob / lever of the split casing The casing adjustment knob and lever for the transfer of motion from the lead screw to the tool holder carriage (see Figure 21), are located at the sides of the tool holder carriage itself. Figure 21 –...
MACHINES AND ACCESSORIES 9.2.4 Levers and handwheels of the carriage and tool holder slides On the tool holder carriage there are five manual controls (levers and handwheels) for carrying out fine adjustments and feeding (see Figure 22). Figure 22 – Lever and handwheel of the carriage. Split casing lever : See section 9.2.3.
MACHINES AND ACCESSORIES Lever for activating and selecting the direction of rotation of the electric motor: The lever selects activation and the direction of rotation of the electric motor and the other rotating parts (spindle). Move the lever down to rotate the spindle clockwise, move the lever up to turn the spindle anti-clockwise.
MACHINES AND ACCESSORIES 9.3 Mechanical brake pedal of the spindle The machine is equipped with a mechanical brake pedal that slows or stops the rotation of the spindle as required (see Figure 25). Pressing the pedal with your foot, the spindle is immediately braked, while releasing the pedal stops the braking action.
MACHINES AND ACCESSORIES Data cable connections Pay attention to the correct connection of the data cables. If reversed they can cause erroneous readings by the digital display. The display can be rotated and tilted to allow the data to be viewed at any time. Rotation is achieved by simply moving it with one hand, and to adjust the angle, loosen the bolt located just below the power cord, tilt the panel and then retighten the bolt.
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MACHINES AND ACCESSORIES 1- Self-test The display shows the following messages: Model Use with lathe* S D S 2 L A T H E Axis number Resolution * "Lathe" is specified because the panel can be programmed for other tool machines. At the end of the self-diagnostic the display shows the following messages: It could be “INC”...
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MACHINES AND ACCESSORIES After each setting, press the button and to move to the next step. Setting the axis linear encoder measuring direction. d i r Press the button of the axis which you wish to set (X, Y, Z) Press the button for a positive count in the direction of movement from the outside towards the rotation axis.
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MACHINES AND ACCESSORIES Integration of the Y-axis with the Z axis Press the button or the button to change the setting N O N E I N G R E A T After the selection press the buttons to move to the next step. By integrating the Y and Z dimensions (movements on the same axis) only one dimension (Y-axis) will be displayed, which will vary depending on whether you are...
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MACHINES AND ACCESSORIES 4- D EFAULT DATA The default data allows continuous monitoring of the machining in operation. If, for example, it has a piece as shown in Figure 29/a) and you want to get the piece in Figure 29/b) you can set all the heights in order to precisely control the actual machining.
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MACHINES AND ACCESSORIES 5 – Displaying the absolute / relative coordinates Press the buttons to move from the relative coordinates "INC" to the absolute coordinates "ALE" and vice versa, on the display of the Y coordinate. Set the D plane as the reference plane, in this way in "ALE"...
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MACHINES AND ACCESSORIES Press the button (to switch to the relative coordinates) then reset the display of Y, by pressing the buttons. 0. 0 0 0 X I N C 0. 0 0 0 Y Move the cutting tool to the A plane. 0.
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MACHINES AND ACCESSORIES 0. 0 0 0 X A L E 1 3 0. 0 0 0 Y Move the cutting tool to the D plane. 0. 0 0 0 X A L E 0. 0 0 0 Y 6 – Viewing stored coordinates ...
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MACHINES AND ACCESSORIES 7 – Radius / Diameter display Figure 31 – Radius / Diameter display The reference for axis X is the axis of spindle rotation (dashed line in Figure 31). Move the cutting tool to point A. 5. 0 0 0 X Press the buttons to switch from viewing the radius to the diameter.
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MACHINES AND ACCESSORIES 8 – Displaying Metric / Imperial coordinates The digital panel can also show the coordinates of the X axis in Imperial units (inches), this display is not available for the Y axis With reference to Figure 32, proceed as follows, to switch from Metric coordinates to Imperial coordinates.
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MACHINES AND ACCESSORIES 9 – Linear error compensation The linear error compensation function is used for the correction of errors in the transmission system of the lead screw. The correction factor is expressed as: 1000 where L ...
10 OPERATION Intended use and materials The Gear head lathe (Art. T999/230V and T999/400V) has been designed and constructed for the machining of metallic materials by means of cold chip removal. Any use and lack of respect for the technical parameters established by the manufacturer may be dangerous to operators;...
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MACHINES AND ACCESSORIES Locking the piece Lock the workpiece onto the self-centring spindle in a stable and secure manner, by tightening the jaws with the necessary force. 3. If necessary, secure the opposite end of the workpiece using the tailstock. To do this, adjust the position of the tailstock and quill, using the appropriate fastening lever and hand wheel (see Figure...
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MACHINES AND ACCESSORIES Risk of abrasion and/or cutting After putting the start lever into the neutral position or pressing the emergency stop switches, the spindle will continue to rotate by inertia. For an immediate stop, you must push the brake pedal beneath the bed of the machine. ...
MACHINES AND ACCESSORIES 10.1Automatic Feed Tool Carriage Longitudinal feed The automatic longitudinal feed of the carriage is derived from spindle, which transmits its motion to the grooved bar (see Figure 35). The longitudinal feed is due to the lower slide that drags the carriage in the direction of the axis of the Lathe.
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MACHINES AND ACCESSORIES Longitudinal feed for threading: The automatic longitudinal feed originates in the spindle, which transmits motion to the lead screw connected to the spindle itself by means of gears that allow for the variation in the rotational speed (see Figure 37).
MACHINES AND ACCESSORIES 11 MAINTENANCE Electric shock Before maintenance or checks, turn off the machine and ALWAYS unplug the power cord. This is so that there is no risk of electric shock. Regularly clean and take care of the machine to guarantee proper efficiency and a long working life.
MACHINES AND ACCESSORIES 11.1Lubrication It is good practice to clean the machine, especially the guides, removing all chips produced by the work. Apply, with a rag or a brush, a thin layer of oil on the guides and on the spindle to prevent corrosion.
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MACHINES AND ACCESSORIES For proper lubrication of the Lathe, proceed as follows (see Figure 39): Top up the level Oil level windows Figure 39 – Lubrication points on the machine. Lubricatio Type Replacemen Parts of the machine Frequency n point lubricant t frequency Feed shaft...
MACHINES AND ACCESSORIES Lubricatio Type Replacemen Parts of the machine Frequency n point lubricant t frequency Carriage rails Oil 20 Daily Level Gears for threading Oil 20 6 months indicator Types of oil recommended Mobil Vectra No. 2 Shell – Tonna – T68/TX68 Chevron –...
MACHINES AND ACCESSORIES 11.3.2 Tailstock alignment When the tailstock is off-axis, it is necessary to correct its position by turning the adjustment screw until aligned with the reference marks on the side plate. Figure 41 – Adjustment screw. 11.3.3 Spindle alignment When the spindle rotates off-axis or if particularly heavy machining operations must be carried out, make an adjustment to the bearings.
MACHINES AND ACCESSORIES 11.3.4 Adjusting the slack of the gears It is very important that there is no abnormal slack between the gears, to avoid breakage or rapid wear of the teeth of the gears themselves. To reduce and / or adjust the slack , move the gear II and firmly tighten nuts III and IV (see Figure 43 Figure 43 –...
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MACHINES AND ACCESSORIES Part No. Description Part No. Description T999/B017 T999/B065 Shaft T999/B018 O-ring T999/B066 T999/B019 Locking screw T999/B067 Bearing cover T999/B020 Selector T999/B068 Gasket T999/B021 Support T999/B069 Gear T999/B022 Selector T999/B070 Gear T999/B023 Support T999/B071 Brass bushing T999/B024 Support T999/B072 Gear T999/B025...
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MACHINES AND ACCESSORIES TABLE C Page 65 of 84 www.EngineeringBooksPDF.com...
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MACHINES AND ACCESSORIES Part No. Description Part No. Description T999/C001 Collar T999/C046 Small pin T999/C002 Collar T999/C047 T999/C003 Back cover T999/C048 Shaft T999/C004 Back cover T999/C050 Gear 51z T999/C005 Pulley T999/C051 Spacer T999/C006 T999/C052 Shaft T999/C007 Head T999/C053 Gear 30 z T999/C008 Front cover T999/C054...
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MACHINES AND ACCESSORIES Part No. Description Part No. Description T999/C042 Gear 74z T999/C102 Nut M12 T999/C043 Gear 37z T999/C103 Key 5 x 15 T999/C044 Shaft T999/C104 Key 5 x 18 T999/C045 Spring T999/C105 Key5 x 50 T999/C106 Key 6 x 40 T999/C131 O_Ring T999/C107...
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MACHINES AND ACCESSORIES TABLE D Page 70 of 84 www.EngineeringBooksPDF.com...
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MACHINES AND ACCESSORIES Part No. Description Part No. Description T999/D001 Motor support T999/D069 Plug T999/D002 Pulley T999/D070 Bolt T999/D003 Table T999/D071 Bolt T999/D004 Cavity T999/D072 Bolt T999/D005 Protective device T999/D073 T999/D006 Support T999/D074 Electrical controls box T999/D007 Support T999/D075 Splashguard T999/D008 Spacer T999/D076...
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MACHINES AND ACCESSORIES Part No. Description Part No. Description T999/D061 Plug T999/D109 Screw T999/D061A Plug T999/D110 T999/D067 Spring T999/D111 Rod support T999/D068 Sphere Page 73 of 84 www.EngineeringBooksPDF.com...
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MACHINES AND ACCESSORIES TABLE E Page 74 of 84 www.EngineeringBooksPDF.com...
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MACHINES AND ACCESSORIES Part No. Description Part No. Description T999/E001 Saddle T999/E042 Bearing T999/E002 Slide T999/E043 Bearing T999/E003 Rotating slide T999/E044 Screw T999/E004 Upper slide T999/E045 Screw T999/E005 Collar T999/E046 Screw T999/E006 T999/E047 Screw T999/E007 T999/E048 Allen key T999/E008 Strip T999/E049 Allen key T999/E009...
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MACHINES AND ACCESSORIES TABLE F Page 77 of 84 www.EngineeringBooksPDF.com...
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MACHINES AND ACCESSORIES Part No. Description Part No. Description T999/F001 Body T999/F022 Micrometer T999/F002 Flange T999/F023 Lock T999/F003 Hand wheel T999/F026 Switch T999/F004 Plate T999/F029 Knob T999/F005 Base T999/F030 Knob T999/F007 Sleeve T999/F031 Allen key T999/F008 Screw T999/F032 Allen key T999/F009 Washer T999/F033...
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MACHINES AND ACCESSORIES TABLE G TABLE H Page 79 of 84 www.EngineeringBooksPDF.com...
MACHINES AND ACCESSORIES 13 DISPOSAL OF PARTS AND MATERIALS If the machine is to be scrapped, its parts must be disposed of differently. The Lathe is composed of the following materials: the head, the table, the tailstock, the slides and the carriages are made of cast iron; ...
MACHINES AND ACCESSORIES 14 TROUBLESHOOTING PROBLEM PROBABLE CAUSE SOLUTION A) Damaged bearings. B) Contact Customer Service. B) Bearings not lubricated. C) Lubricate Noisy operation C) Blunt tool. D) Remove/sharpen the tool. D) Loose tool. E) Tighten the fastening lever. A) Electrical power supply. Check mains power...
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