Knuth DLE 800 Operating Instructions Manual

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Mach Tools

OPERATING INSTRUCTIONS

OPERATING

INSTRUCTIONS

DL E 800

Part No

300512

300514-300516

For the important safety of your body, please read this manual book and understand its contents

before operation.

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Summary of Contents for Knuth DLE 800

Page 1 Mach Tools OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS DL E 800 Part No 300512 300514-300516 For the important safety of your body, please read this manual book and understand its contents before operation.
Page 2 Mach Tools OPERATING INSTRUCTIONS Security instruction Operation manual For your own security read the operation manual before starting the machine. The operation manual should be kept in a secure place. You should know about how to handle the machine, it’s limits and it’s specific dangers.
Page 3 Mach Tools OPERATING INSTRUCTIONS Take care about the Power supply cable Before connecting the power supply cable to the wall socket ensure that the machine is switched off. Don’t use the cable to pull the plug out of the socket. Take care, that there is no tensile force on the cable.
Page 4 Mach Tools OPERATING INSTRUCTIONS Mending may only be done by electric specialist to prevent accidents for the user. Cleaning solvent Before you work with cleaning solvent you should read the instruction of the fluid, to prevent accidents. Leaving the machine Never leave the machine while it is running.
Page 5 Total 4 CONTENT LIST Page 1 Chapter 1 Operational requirements and safe measures Chapter 2 Application and features Drawing 2.1 2.1 Machine outlook 2.2 Machine applications 2.3 Machine features Chapter 3 Machine parameters and specifications 3.1 Main specifications Table 3.1 3.2 Headstock 3.3 Feedbox 3.4 Tool post...
Page 6 Total 4 CONTENT LIST Page 2 6.2 Spindle structure and its adjustment Drawing 6.2 6.3 Axis I structure and direction change Drawing 6.3 6.4 Spindle brake device Drawing 6.4 Chapter 7 Tailstock 7.1 Tailstock features Drawing 7.1 7.2 Rapid device for tailstock Drawing 7.2 Chapter 8 Saddle and tool post 8.1 Features of saddle and tool post...
Page 7 Total 4 CONTENT LIST Page 3 Chapter 10 Feedbox Drawing 10.1 10.1 Feedbox features Drawing 10.2 10.2 Adjustment of thread and feed rate Drawing 11.1 Chapter 11 Change gear Table 11.1 11.1 Change gear device 11.2 Adjustment of change gear for various thread-turning and feed Drawing 13.1 Drawing 14.1...
Page 8 Total 4 CONTENT LIST Page 4 Chapter 19 Electric system and electric device Drawing 19.1~19.3 19.1 Instruction on electric control 19.2 Drawing of electric operation 19.3 Instruction on electric protection Tables 19.1, 19.2 19.4 Main electric elements Chapter 20 Hydraulic system Drawing 20.1 20.1 Hydraulic system functions 20.2 Work theory of hydraulic system...
Page 9 Total 5 CHAPTER 1 USAGE REQUIREMENTS AND SAFE MEASURES Page 1 1. Technical training and practical operation 1.1 Operator should attend technical training before practical operation. 1.2 Before first operation operator should refer to operational manual so as to wholly know structure, performance, control, and maintenance of machine and so 1.3 Before operation, operator should inspect whether each sliding surface of machine is clean or not, whether there is enough lubricant, and whether hydraulic and lubrication devices are normal.
Page 10 Total 5 CHAPTER 1 USAGE REQUIREMENTS AND SAFE MEASURES Page 2 1.8 Speed-varying handle should be turned to proposed position according to machine nameplate. When gear in headstock or feedbox is in operation, changing running speed or feed rate is not allowed. 1.9 When rapid traveling tool post, please to confirm crossed handle direction on apron coincides with traveling direction of tool post, then press button at end of handle.
Page 11 Total 5 CHAPTER 1 USAGE REQUIREMENTS AND SAFE MEASURES Page 3 Be connected according to requirement (if electric cabinet is with earthed protection, earthed wire for machine may be unnecessary). Voltage of electric net should be within AC380V±15% to ensure normal work. 2.
Page 12 Total 5 CHAPTER 1 USAGE REQUIREMENTS AND SAFE MEASURES Page 4 2.8 Machine maintenance should be performed after machine stops. 2.9 Maintainer should clearly know machine component, and they should master enough knowledge about mechanics, electricity and hydraulics. 2.10 When maintaining or changing electric element, power supply should be turned off.
Page 13 Total 5 CHAPTER 1 USAGE REQUIREMENTS AND SAFE MEASURES Page 5 3.8 When operating, protector of change gear should be closed, which could prevent operator from accident for suddenly cut-off of power. 3.9 Operator should keep positions of all emergency-break button in mind in order to protect against all eventualities.
Page 14 Total 2 Chapter 2 MACHINE APPLICATIONS AND ITS FEATURES Page 1 2.1 Machine outline It is shown as drawing 2.1. DRAWING 2.1 MACHINE OUTLINE 2.2 Machine applications This machine is suitable for various turning, such as cylinder, inner bore, end and various formed surfaces: metric thread, Whitworth thread, module thread and diametric thread.
Page 15 Total 2 Chapter 2 MACHINE APPLICATIONS AND ITS FEATURES Page 2 noise, strong rigidity, good accuracy and accuracy persistence, but also external features of beautiful outline and compact arrangement. Furthermore, it also has advantages of integral handles, figurative nameplate, convenient operation, safety, reliability, user orientation.
Page 17 Total 4 Chapter 3 MACHINE SPECIFICATIONS AND PARAMETERS Page 1 3.1 Main specifications Machine model DL E 620 DL E 800 Φ1250mm Φ1400mm Φ1600mm Max. swing over bed Max. workpiece length L=1500 2000 3000 5000 6000 8000 9000 (mm) Max. turning length L’=L-175mm Φ900mm Φ1100mm...
Page 18 Total 4 Chapter 3 MACHINE PARAMETERS AND SPECIFICATIONS Page 2 Cross (a half of longitudinal feed rate) 0.05~6mm/r Top tool post(a fourth of longitudinal feed rate) 0.025~3mm/r Kind of metric thread 56kinds Range of metric thread pitch 1~120mm Kind of inch thread 56kinds Range of tooth number per inch for inch thread 30~1/4 /inch...
Page 19 Total 4 Chapter 3 MACHINE PARAMETERS AND SPECIFICATIONS Page 3 Middle tool post 935mm/min 3.5 Tailstock Φ160mm Diameter of tailstock sleeve Max. travel of tailstock sleeve 300mm Taper bore of tailstock sleeve Metric no.180 Cross movement of tailstock 2.5mm Tailstock sleeve movement per revolution of hand-wheel: Rapid 8mm/r slow 0.4mm/r 3.6 Motor device...
Page 22 Total 1 Chapter 5 Page 1 Bed structure is as drawing 5.1 shown. Bed section is enclosed, so bed has strong rigidity and good chip-conveying functions. Section o f bed guide way is rectangular and symmetric V-shaped. Large V-shaped guide way 1 and rectangular guide ways 4 combine one group, which is used for longitudinal travel of saddle.
Page 23 Total 5 Chapter 6 HEADSTOCK Page 1 6.1 Headstock features As drawing 6.1 shown, axes group in headstock are well arranged, which are easy for mounting, adjustment, control and maintenance. Drive parts are located on optimum radial positions of spindle, and its axial locations are near to sensitive points, drive force has no effect on overhanging end of spindle, so spindle rigidity is greatly improved.
Page 24 Total 5 Chapter 6 HEADSTOCK Page 2 front and back supports, auxiliary supported by middle support. As far as front support, radial and axial positioning are by D3182140 and two D8144 bearings respectively. While for back support, radial positioning is by D3182134 bearing. Middle support adopts E12736 bearing.
Page 25 Total 5 Chapter 6 HEADSTOCK Page 3 6.3 Structure and direction shift of axis I Axis I structure is as drawing 6.3 shown. DRAWING 6.3 AXIS I STRUCTURE Axis I is mainly for speed change and direction shift of spindle, which is the first base group for spindle speed change.
Page 26 Total 5 Chapter 6 HEADSTOCK Page 4 When speed-varying handle for forward and reverse rotation on front of headstock is in position of forward rotation, spindle could obtain 2 different speeds of forward rotation: high speed 45/45 low speed 40/50 It is as drawings 4.1 and 6.3 shown.
Page 27 Total 5 Chapter 6 HEADSTOCK Page 5 6.4 Brake device for spindle DRAWING 6.4 SPINDLE BRAKE STRUCTURE It is as drawing 6.4 shown. Brake device for spindle is on end of axis III, it adopts friction discs controlled by hydraulic device, and it features of sensitive brake, rapid speed, safe and reliability.
Page 28 Total 2 Chapter 7 TAILSTOCK Page 1 7.1 Tailstock features It is as drawing 7.1 shown. Axial travel of tailstock sleeve includes 2 steps of high and low speed. When handle 2 turns to 1:1 position, tailstock sleeve axially travels 8mm per revolution of handle 1.
Page 29 Total 2 Chapter 7 TAILSTOCK Page 2 When holding workpiece with tailstock, operator should turn block-pin handle 4 to make block-pin insert bed rack, then fasten nut 5 and sleeve-locking handle 6. When tailstock need to travel longitudinally (especially mechanical rapid travel), firstly to screw off nut(looseness should be proper), and loosen handle 4 of locking pin and touch-stop stopper between saddle and tailstock, then travel tailstock mechanically.
Page 30 Total 4 Chapter 8 SADDLE AND TOOL POST Page 1 8.1 Features of saddle and tool post Structure of saddle and tool post is as drawing 8.1 shown. Tool post of this machine has manual and mechanical functions. Guide ways of saddle are coated with soft strip made of polyvinyl fluoride. So saddle has features of good anti-weariness, fine vibration absorption, smooth movement, easy and labor-saving operation.
Page 31 Total 4 Chapter 8 SADDEL AND TOOL POST Page 2 When taper length is more than 400mm, turning could be realized with combined motion of longitudinal feed of saddle and feed of middle tool post. When turning this kind of taper, cover for crossed slot of single handle on right of apron should make rotation of 45º, to do that forms a included angle of 45º...
Page 32 Total 4 Chapter 8 SADDLE AND TOOL POST Page 3 8.4 Adjustment of nut clearance It is as drawing 8.3 shown. Nut of lead screw on slide is split, when appear overlarge clearance for wear between lead screw and nut, fasten screw 1 to make nut 2 be with elastic deformation, so as to eliminate clearance between lead screw and nut.
Page 33 Total 4 Chapter 8 SADDEL AND TOOL POST Page 4 As drawing 8.4 shown, with rotary button 1 to change modes between mechanical and manual feed for top tool post. When changing, pull rotary button 1 out about 5mm, and make a rotation of 180º, then rotary button automatically resets, tool post changes manual feed to mechanic feed.
Page 34 Total 3 Chapter 9 APRON Page 1 9.1 Apron features Aprons of engine lathes of serial DL E are as drawing 9.1 shown, which have features of simple structure, flexible operation, safety and reliability. Longitudinal/cross feed and rapid travel are all controlled by single handle which could move around.
Page 35 Total 3 Chapter 9 APRON Page 2 9.2 Rapid device of apron DRAWING 9.2 RAPID DEVIEC OF APRON Apron is with device for longitudinal /cross rapid travel, which is driven by single motor. In order to prevent feed system and rapid travel from interference, left of worm axis in apron case is mounted with overload clutch, as drawing 9.2 shown.
Page 36 Total 3 Chapter 9 APRON Page 3 could be locked. When single handle 5 is at any direction of crossed slot, because certain position of axis 2 or axis 3 offsets or rotates, then cams on axis 1 could not insert into slots of axis 2 and axis 3.
Page 37 Total 2 Chapter 10 FEEDBOX Page 1 10.1 Feedbox features Feedbox of engine lathe of CW serial adopts device of double-axis sliding gears, Among them, 8 gears for pitch modulation, 4 basic gears, so this kind of gearbox has wide pitch range. Basic group is controlled by cam, it has features of easy operation, the smallest travel for sliding gears, regular serial pitches.
Page 38 Total 2 CHAPTER 10 FEEDBOX Page 2 Module thread J=πmz/IT equation(4) Inch thread J=25.4z/ITN equation(5) Diametral pitch thread J=25.4πz/ITP equation(6) J – transmitting ratio of change gear I-feed transmitting ratio N-thread number of workpiece per inch m-module(mm) T –lead screw pitch(mm) Z-number of threads P- diametral pitch of workpiece t- workpiece pitch (mm)
Page 39 Total 2 CHAPTER 11 CHANGE GEAR Page 1 11.1 Change gear device Change gears not only transmit feed force source, but also turn various threads. See drawing 11.1. DRAWING 11.1 CHANGE GEAR DEVICE...
Page 40 Total 2 CHAPTER 11 CHANGE GEAR Page 2 11.2 Arrange of change gears for various threads and feeds, please see table 11.1...
Page 41 Total 1 CHAPTER 12 SAFETY PROTECTION Page 1 1. In apron is mounted with touch-stop device(see drawing 9.3). During apron travels, when touch-stop stick touches stopper fastened on bed, push lever in apron to reset feed handle 5, so feed stops. This device not only takes effect of terminal protection, but also limits travel for cutting, and positioning accuracy is within ±1mm.
Page 42 Total 1 CHAPTER 13 MANUAL BRACKET Page 1 This bracket is used for supporting lead screw and feed rod of lathe longer than This bracket is positioned by large V-shaped guide way, two bushes support lead screw and feed rod, it is as drawing 13.1 shown. When rotate handle 1, workpiece 2 may move up and down, then support and release lead screw and feed rod.
Page 43 Total 1 CHAPTER 14 LUBRICATION SYSTEM Page 1 DRAWING 14.1 MACHINE LUBRICATION Lubrication system of this system adopts external-circulated forced lubrication, oil mist lubrication and oil-input lubrication(including input grease). In order to improve service life of machine and insure normal operation of machine, operator must regularly input oil and change oil according to drawing 14.1.
Page 44 Total 1 CHAPTER 16 COOLING SYSTEM Page 1 Cooling system of this machine includes coolant tank, electric pump, soft and hard tubes, valve, nozzle and so on. Because of oil-backing tube is buried under the ground, and coolant tank beside machine is also under ground, so working environment is easily to remain.
Page 46 Total 5 CHAPTER 17 MACHINE TRANSPORTATION, INSTALLMENT AND TEST RUN Page 1 17.1 Transportation of machine When lifting case with machine with lifter, steel wire should be used as mark on case. When transporting and lifting, bottom and side of case should be against overlarge vibration.
Page 50 Total 5 CHAPTER 17 MACHINE TRANSPORTATION, INSTALLMENT AND TEST RUN Page 2 17.2 Machine installment When max. workpiece length is not more than 6m, side-holding and raiser block are unnecessary, what is needed is to place a steel plate of 60mm x 60mm x 10 mm under each adjustable screw.
Page 51 Total 5 CHAPTER 17 MACHINE TRANSPORTATION, INSTALLMENT AND TEST RUN Page 4 Before delivery, machine has passed through all inspection and test. Because correct installment directly affects machine accuracy, operator should notice the followings: when installing machine, foundation should be done firstly as requirement in drawing 17.3(foundation depth is dependent on local earth quality), and oil-backing tube should be installed.
Page 52 Total 5 CHAPTER 17 MACHINE TRANSPORTATION, INSTALLMENT AND TEST RUN Page 5 DRAWING 17.4 INSPECTION OF INSTALLATION ACCURACY 17.4 Machine test run After finishing installment, operator should clean away anti-rust grease with kerosene and cotton yarn, and coat anti-rust grease on each machining surface. To scrape machine with emery cloth or hard article is not allowed.
Page 53 Total 3 CHAPTER 18 ADJUSTMENT OF MAHCINE SPEED AND FEED RATE Page 1 Speed change of spindle is reached by combination of buttons and handles on headstock, relationship between spindle speed and work capacity sees table 18.1. Change of various threads and feed rate is reached by combination of handle for coarse pitch, shift handle for left and right threads on headstock, and handles on feedbox.
Page 60 Total 7 CHAPTER 19 ELECTRIC SYSTEM AND ELECTRIC DEVICE...
Page 61 Page 1 19.1 Instruction on electric control This machine uses power of 50~60Hz, 3 phases and 220V~420V (Specific supplied voltage and frequency must comply with defined parameters on electric nameplate of electric cabinet), control power is AC24V, power for electromagnet is DC24V.
Page 62 Page 2 DRAWING 19.1 CONTROL BUTTON 19.2 Instruction on electric operation Operational procedure for electric system refers to drawings 19.2 and 19.3. Firstly, switch on main power switch QF1 on left-up of electric cabinet, then switch on oil pump switch QF4 on right of electric cabinet to make oil pump operate normally, and press button SB6 for main motor to start main motor.
Page 63 for shift between forward and reverse rotation on front of headstock to make it be in position of forward rotation, then press button for high-speed forward rotation of spindle(same as button of SB11 or SB12 for reverse rotation) to forward rotate spindle at high speed without stopping.
Page 64 20.1 Function of hydraulic system: It is used for control of forward, reverse rotation of spindle, brake, lubrication of gear and bearing in headstock and feedbox. 20.2 Work theory of hydraulic system: Hydraulic system is composed of two electromagnetic selector valves 34D-10BY, 24D-10B, relief valve, oil filter and pressure meter and so on.
Page 65 through 1-4-5-7(or 8), after power supply is cut off, Oil backs oil tank through 7-6(or 8-6). DRAWING 20.1 HYDRAULIC SYSTEM THEORY 20.3 Maintenance for hydraulic system This system uses pure engine oil of no. 20. In order to ensure cleanness of oil, oil should be filtered before input, and oil filters in oil tank and on valve plate should be regularly (in 2 months) cleaned.
Page 80 Oiling oft he bearings Attention Oiling of the bearings: Oil the bearings once per week! Volume of oil 1. Screw tos et the volume oft he oil to support 2. Volume will be regulated...
Page 81 3. Block of oil to support( If the screw is closed there is no fluid going to the support 4. Distributer 5. Distributer 1-2-3 5a Distributer 1-2 to oil the guideways of the machines body. 5a Distributer 3 to oil the coupling...
Page 82 6. Distributer 1-2 to oil the guideways of the machines body. 7. Distributer 3 to oil the coupling 8. Screw to fill oil in the support.

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