Table of contents Safety Type plate ..............................6 Safety instructions (Warning notes)......................7 1.2.1 Classification of hazards...........................7 1.2.2 Other pictograms ............................7 Intended use .............................8 Reasonably foreseeable misuse.......................8 1.4.1 Avoiding misuses............................9 Possible dangers caused by the lathe ......................9 Qualification ..............................9 1.6.1 Target group private users........................9 1.6.2 Obligations of the User ...........................10 1.6.3 Additional requirements regarding the qualification................10 Operators positions..........................10...
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4.2.1 Switching elements ..........................23 4.2.2 Switching on the machine ........................24 4.2.3 Switching off the machine ........................24 4.2.4 Clamping the tool ........................... 25 4.2.5 Replacing the clamping jaws on the lathe chuck..................26 4.2.6 Spindle nose............................27 4.2.7 Mounting of rests............................ 28 4.2.8 Use of collet chucks ..........................
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Appendix Copyright ..............................73 Terminology/Glossary..........................73 Change information operating manual....................73 Liability claims for defects / warranty ......................74 Storage ..............................75 Note regarding disposal / options to reuse .....................75 8.6.1 Decommissioning ...........................75 8.6.2 Disposal of the packaging of new devices....................76 8.6.3 Disposing of the old device........................76 8.6.4 Disposal of electrical and electronic components...................76 8.6.5 Disposal of lubricants and coolants ......................76 Disposal via municipal collection ......................77...
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Dear customer, Thank you very much for purchasing a product made by OPTIMUM. OPTIMUM metal working machines offer a maximum of quality, technically optimum solutions and convince by an outstanding price performance ratio. Continuous enhancements and prod- uct innovations guarantee state-of-the-art products and safety at any time.
Always keep this documentation close to the lathe. INFORMATION If you are unable to solve a problem using these operating instructions, please contact us for advice: Optimum Maschinen Germany GmbH Dr. Robert-Pfleger-Str. 26 D- 96103 Hallstadt Email: info@optimum-maschinen.de...
Safety instructions (Warning notes) 1.2.1 Classification of hazards We classify the safety warnings into various levels. The table below gives an overview of the classification of symbols (ideogram) and the warning signs for each specific danger and its (possible) consequences. Ideogram Warning alert Definition / consequence...
the inspection and maintenance instructions are observed. Technical data on page 16 In order to achieve optimum cutting performance, it is essential to choose the right turning tool, feed, tool pressure, cutting speed and coolant. WARNING! Heaviest injuries due improper use.
Any other use has to be discussed with the manufacturer. It is only allowed to process metal, cold and non-inflammable materials with the lathe. In order to avoid misuse, it is necessary to read and understand the operating instructions before the first commissioning. The operators must be qualified.
Vocational training or further instruction 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.
It is your responsibility! If a safety device has been activated or has failed, the lathe must only be used if you the cause of the failure has been removed, you have made sure that there is no existing danger for personnel or objects. WARNING! If you bypass, remove or override a safety device in any other way, you are endangering yourself and other persons working on the machine.
1.10.2 Protective cover with safety switch The spindle head of the lathe is equipped with a fixed, separating protective cover. The locked position is monitored by means of an electrical limit switch. Protective cover INFORMATION It is not possible to start the machine until the protective cover is closed.
1.10.3 Lathe chuck protection with position switch The lathe is provided with a lathe chuck protection. lathe only switched on if the lathe chuck protection is closed. Lathe chuck pro- tection closed Lathe chuck pro- tection open integrated Position switch Img.1-4: Lathe chuck protection 1.10.4 Lathe chuck key...
INFORMATION Use the following table in order to organize the checks. General check Equipment Check Protective covers Mounted, firmly bolted and not damaged Signs, Installed and legible Markings Date: checked by (signature): Functional check Equipment Check EMERGENCY-STOP When the EMERGENCY STOP push button is activated, the switch lathe must switch off.
For clamping workpieces, only use the special chuck key supplied. Mind the maximum chuck opening. Wear safety goggles. Do not remove the turning chips by hand. Use a chip hook and / or a hand brush to remove turning chips.
Technical data The following information are the dimensions and indications of weight and the manufacturer‘s approved machine data of lathe TU2004V. Electrical connection Connection 230V ; 600 W ~ 50Hz Machine data Height of centres [mm] Swing over lathe bed [mm] Max.
Emissions Maximum sound pressure level at 1 m distance 75 dB(A) in idle running from the machine and 1.60 m above the ground. CAUTION! The machine operator should use hearing protection. INFORMATION This numerical value was measured on a new machine under the operating conditions specified by the manufacturer.
Delivery, interdepartmental transport and unpacking CAUTION! Injuries caused by parts falling over or off a forklift, pallet truck or transport vehicle. Only use means of transport that can carry the total weight and are suitable for it. Notes on transport, installation and unpacking Improper transport of individual devices and minor machines, unsecured devices and minor machines stacked on top of each other or next to each other in packed or already unpacked condition is accident-prone and can cause damage or malfunctions for which we do not grant...
Unpacking the machine Transport the lathe in its packing crate to a place near its final installation location before unpacking it. If the packaging shows signs of possible transport damage, take the necessary precautions not to damage the machine when unpacking. If any damage is discovered, the car- rier and/or shipper must immediately be notified of this fact to establish any claim which might arise.
Also consider that the machine is accessible for setting and maintenance works. The mains plug and the main switch of the lathe has to be freely accessible. Provide for sufficient illumination (Minimum value: 300 lux). In case of little intensity of illumination provide for additional illumination i.e. by a separate workplace illumination.
Grease the lathe according to the lubrication chart. Inspection and maintenance on Control the function of page 53 movable and fixed parts. Check if all spindles are running smoothly. check Control if the fastening screws of the lathe chuck are firmly tightened. ...
Operation Control and indicating elements Pos. Designation Pos. Designation Turning direction selector Emergency stop button Rotation speed indicator Push button ON / OFF for the protective cover of the headstock Lathe chuck protection Chips shield Lathe chuck Infinitely variable speed adjustment Tool holder Tailstock Clamping screw tailstock sleeve...
Safety Use the lathe only under the following conditions: The lathe is in proper working order. The lathe is used as prescribed. The operating manual is followed. All safety devices are installed and activated. All failures should be eliminated immediately. Stop the immediately in the event of any abnor- mality in operation and make sure it cannot be started-up accidentally or without authorisation.
4.2.2 Switching on the machine CAUTION! Check that the shift lever is not activated for automatic feed. „Img.4-11: Shift lever feed "OFF"“ on page 32 By switching on the lathe with high speed setting and activated shift lever, the lathe slide will move with high speed.
If the machine stands still for a longer period of time, switch off the main switch Img.4-1: Main switch 4.2.4 Clamping the tool Clamp the lathe tool into the tool holder. The lathe tool needs to be clamped as short and tight as possible when turning in order to be able to absorb the cutting force well and reliably during the chip formation.
For the facing process, the cutting edge of the tool must be exactly aligned with the height of the lathe centre to obtain a shoulder-free face. The facing process is a turning opera- tion in which the turning tool feeds perpendicular to the axis of rotation of the work- piece in order to produce a flat surface.
4.2.6 Spindle nose If the machine is cold such as e.g. directly after having transportation, the machine should be warmed up for the first 30 minutes at a spindle speed of only 500 1/min. on page 21 ATTENTION! When disassembling the workpiece carrier, it may fall on the engine bed and damage the guide rails.
4.2.7 Mounting of rests Img.4-5: follow rest steady rest 4.2.8 Use of collet chucks When using collet chucks to clamp the workpiece higher machining tolerances are available. The exchange of collet chucks for a smaller or larger diameter is simple and can be easily per- formed.
Speed adjustment Adjust the speed with the potentiometer. In order to use another speed range, you must change the position of the synchronous belt on the pulleys. WARNING! Unplug the shockproof plug of the lathe before opening the protective cover of the headstock.
Img.4-7: Synchronous belt position change Adjusting feeds and thread pitches In order to achieve a change of feed of a certain thread pitch, the change wheels are to be changed according to the table. Toothed wheel of You will find the complete table on the departure lathe.
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Swing the quadrant to the right. Img.4-9: Locking screw quadrant Example of the transmission ratio: i The thread pitch of the lead screw amounts to 2mm. Example of thread pitch: 1.25mm 40 x A x D 40 x 66 x 50 i = 2x = 2x = 1.25mm...
4.4.1 Switching on the feed CAUTION! By switching on the lathe with high speed setting and activated shift lever, the lathe slide will move with high speed. Engaging lever Position automatic feed "OFF" Img.4-11: Shift lever feed "OFF" CAUTION! If you switch on the for instance at full speed of 2500min with the order of the toothed wheels for thread pitch 1.25mm, the lathe saddle will travel a distance of 52 mm within one second.
Lathe saddle Pos. Designation Pos. Designation Quadruplicate tool holder Cross slide Handwheel cross slide Handwheel lathe saddle Top slide Handwheel top slide Lathe saddle Feed activation lever Tightening screw lathe saddle The handwheel (4) is used to traverse the lathe saddle manually. The cross slide (2) can be advanced and returned by turning the cross slide handwheel (3).
4.5.1 Turning short tapers with the top slide With the top slide short 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. ...
4.5.3 Turning of cones with high precision D = large diameter [mm] 2 d = small diameter [mm] L = cone length [mm] Lw = workpiece length [mm] = cone angle 2 = setting angle Kv = cone proportion Vr = tailstock offset Vd = measure change [mm]...
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The infeed is performed with the handwheel of the top slide. The depth of cut is advanced with the handwheel of the cross slide. Gauge Stop measure 100mm Limit stop Measuring direction Advance of depth of cut Img.4-14: Cone setting with stop measure 3.
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4. By offsetting the tailstock as the cone length is larger than the adjustable stroke of the top slide. The workpiece is clamped between two points, therefore center holes are required on the face. They are to be drilled before removing the lathe chuck. The slaving of the workpiece is per- formed by a pulling pin and a lathe carrier.
Tailstock sleeve The tailstock sleeve is used to hold the tools (bits, lathe centres, etc.) The sleeve of the tailstock can a drill chuck used for the recording of drilling and countersinking tools are set. Clamp the required tool in the tailstock sleeve. ...
Standard values for cutting data when turning The better the cutting data are selected, the better the turning result. Some standard values for cutting speeds of different materials are listed on the following pages. Cutting speed table on page 40 Criteria of the cutting conditions: Cutting speed: Vc (m/min) Depth of cut: ap (mm)
+6° to +24° +5° to +11° +5° to +24° 4.10.2 Types of cutting form levels They are needed to influence the chip drain and the chip shape in order to achieve optimum chipping conditions. Examples of types of cutting form levels ...
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Img.4-25: Negative apex angle for roughing The ready-ground major cutting edge must be slightly ground with a grindstone for the plan- ing. For the roughing, a small chamfer must be produced with the grindstone in order to stabilize the cutting edge against striking chips (b = f x 0.8).
Img.4-28: Polished section for threading 4.11 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.
1“ – 11 ½“ NPT Cone Bolt 4.12.1 Metric threads (60° flank angle) pitch P depth of thread of the bolt h2=0.6134 x P depth of thread of the nut H1 = 0.5413 x P rounding r = 0.1443 x P Bolt flank diameter d2 = D2 =d - 0.6493 core removing hole drill = d - P...
4.12.2 British thread (55° flank angle) BSW (Ww.): British Standard Withworth Coarse Thread Series is the most common coarse thread in Great Britain and corresponds in its usage category to the metric coarse-pitch thread. The designation of a hexagon head screw 1/4" - 20 BSW x 3/4" , is here: . 1/4" is the nominal diameter of the screw and 20 is the number of threads in 1"...
Pitch angle Pitch ---------------- - Abb.4-37: Pitch angle 4.12.4 Examples for thread cutting As an example, a metric external thread M30 x 1.0 mm made of brass is being machined. Selecting the tool holder For lathe TU1503V and TU1804V , TU2004V, turning tool No.6 and for lathe TU2404 , TU2404V, TU2506 , TU2506V, TU2807 , TU2807V turning tool No.13.
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The outer diameter had been turned to 30.0mm and the tool holder is clamped in the quadruple holder for thread- ing aligned angular to the rotation axis. The height of cen- tres is checked (as described). Abb.4-38: Thread cutting The depth of thread is manufactured in various passes.
Starting the threading: Radial infeed over the handwheel of the cross slide. Turn the change-over, switch to the right Start the machine and have the first cutting process run. ATTENTION! Always have the thumb ready on the OFF-switch in order to prevent a collision with the workpiece or with the clamping chuck ! ...
Maintenance In this chapter you will find important information about Inspection Maintenance Repairs of the lathe. ATTENTION ! Properly performed regular maintenance is an essential prerequisite for operational safety, failure-free operation, long durability of the lathe and ...
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Interval Where? What? How? Lubricate the lubricating nipples on the lathe saddle. Lubricating nipple every week Lubricating Img.5-1: Lathe saddle Control if the synchronous belts are porous or worn. half-yearly Visual inspection Readjust the guide clearance of the top slide. Readjusting screws as required Readjusting...
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Interval Where? What? How? The set screw widens the flanks of screw thread of the spindle nut. If required, turn the set screw only slightly. A too widened set screw will lead to excessive wear. Fixture spindle nut Set screw as required Readjusting Img.5-4:...
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.
Ersatzteile - Spare parts Ersatzteilbestellung - Ordering spare parts Bitte geben Sie folgendes an - Please indicate the following : Seriennummer - Serial No. Maschinenbezeichnung - Machines name Herstellungsdatum - Date of manufacture Artikelnummer - Article no. Die Artikelnummer befindet sich in der Ersatzteilliste.
Oberschlitten und Planschlitten - Top slide and cross slide 254-1 Img.6-2: Oberschlitten und Planschlitten - Top slide and cross slide TU2004V DE | EN Version 1.0.5 - 2020-08-07 Originalbetriebsanleitung...
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Sechskantmutter Hexagon nut Sicherungsring Locking ring 03420310119 Zwischenwelle Countershaft 03420310120 Rillenkugellager Deep groove ball bearing 608-RZ 040608.2R Riemenscheibe Zwischenwelle Pulley countershaft 03420310122 Sicherungsring Locking ring DIN 471-22 x 1 03420310123 Abdeckung Bottom cover 03420310124 Scheibe Washer Schraube Screw M8x25 Mutter Scheibe Washer Innensechskantschraube...
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Skalenring Scale ring 03420310220 Gewindestift Set screw DIN 915 M6 x 6 Stift 03420310222 Federblech Spring steel sheet 03420310223 Führungsscheibe Guiding disk 03420310224 Hebel Lever 03420310225 Griffhülse Handle 03420310226 Befestigungsschraube Fixing screw 03420310227 Innensechskantschraube Hexagon socket screw DIN 912 M4×8 Gewindestift Set screw DIN 914 M5 x 10...
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Zahnwelle Gear shaft 14 theeth, module 1 03420310312 Welle Shaft 03420310313 44/21 theeth, module 1 / Zahnradkombination Gear combination 03420310314 1,25 Gewindestift Set screw DIN 914 M4×35 Mutter Schlossmutter Apron nut 03420310317 Passstift Alignment pin Æ4 x 10 Innensechskantschraube Hexagon socket screw DIN 912 M4×10 Nachstellleiste 03420310320...
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Zylinderschraube mit Schlitz Slotted cheese head screw 03420310560 Griff Einrückhebel Handle engaging lever 03420310561 Welle Einrückhebel Shaft engaging lever 03420310562 Feder Spring 03420310563 Schlosskasten Handrad linke Apron handwheel left hand 03420310564 Hand Scheibe Washer 03420310565 Klemmhebel Clamping lever 03420310566 Buchse Bushing 03420310568 Schraube...
Malfunctions Malfunctions on the lathe Cause/ Malfunction Solution possible effects Surface of workpiece too • Tool blunt • Resharpen tool rough • Tool springs • Clamp tool with less overhang • Feed too high • Reduce feed • Radius at the tool tip too small •...
Appendix Copyright This document is copyright. All derived rights are also reserved, especially those of translation, re-printing, use of figures, broadcast, reproduction by photo-mechanical or similar means and recording in data processing systems, neither partial nor total. Subject to technical changes without notice. Terminology/Glossary Term Explanation...
- Non reproducible software errors Any services which OPTIMUM GmbH or one of its agents performs in order to fulfill in the frame of an additional guarantee are neither an acceptance of the defects nor an accept- ance of its obligation to compensate. Such services do neither delay nor interrupt the war- ranty period.
Example:not stackable - do not stack a second packing case on top of the first packaging case Consult Optimum Maschinen Germany GmbH if the machine and accessories are stored for more than three months or are stored under different environmental conditions than those given here.
8.6.2 Disposal of the packaging of new devices All used packaging materials and packaging aids of the machine are recyclable and generally need 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.
Modified settings Any experiences with the lathe which might be important for other users Recurring failures Optimum Maschinen Germany GmbH Dr.-Robert-Pfleger-Str. 26 D-96103 Hallstadt Fax +49 (0) 951 - 96 555 - 888 Email: info@optimum-maschinen.de Appendix TU2004V Version 1.0.5 - 2020-08-07...
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EC - Declaration of Conformity Machinery Directive 2006/42/EC Annex II 1.A The manufacturer / distributor Optimum Maschinen Germany GmbH Dr.-Robert-Pfleger-Str. 26 D - 96103 Hallstadt, Germany hereby declares that the following product Product designation: Hand controlled lathe Type designation: TU2004V fulfills all the relevant provisions of the directive specified above and the additionally applied directives (in the following) - including the changes which applied at the time of the declaration.
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Index Target group private users ............9 Classification Technical data of hazards ............7 dimensions ............16 Cleaning and lubricating ........20 Emissions ............17 Control elements ...........23 Environmental conditions ......16 Customer service ..........56 machine data ........... 16 Customer service technician .........56 Thread types ............
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TU2004V Originalbetriebsanleitung Version 1.0.5 - 2020-08-07...
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