Harbor Freight Tools 43681 User Manual

12” x 37” Gap Bed Lathe
Model
43681
ASSEMBLY AND OPERATION INSTRUCTIONS
(Stand Not Included)
Due to continuing improvements, actual product may differ slightly from the product described herein.
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
TO PREVENT SERIOUS INJURY, READ AND UNDERSTAND
ALL WARNINGS AND INSTRUCTIONS BEFORE USE.
Copyright© 2006 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools.
For technical questions or replacement parts, please call 1-800-444-3353.
REV 12/06; 1/07
SPECIFICATIONS
Motor: 2HP, 1700 RPM, Reversible
Power Required: 220 V / 60 Hz, 1-Phase
Drive: Belt/Gear
Swing Over Bed: 12”
Swing Over Gap: 18.8”
Width of Gap: 7”
Center to Center: 37”
Spindle Bore Taper: MT5
Spindle Bore: 1.5”
Three Jaw Chuck Diameter: 6”
Spindle Speed: 18 Speed
Spindle Speed Range:
72; 82; 147; 168; 240; 275; 325; 370; 415; 476;
660; 760; 850; 975; 1080; 1240; 1380; 1600
Bed Way Heat Treatment: 46-52 HRC
Tool Post Type: 4-Position
Max. Tool Shank Size: 3/4” x 3/4” Lathe Bit
Tool Post Travel: Max. 3.5” , 0.001” per scale
Cross Slide Travel: 5.9”, 0.002” per scale
(Total Cut)
Longitudinal Feed Range: 0.005” - 0.0165” /R
(16 Steps)
Cross Feed Range: 0.0014” - 0.0049 /R
(16 Steps)
Tailstock Travel: Max 3.6”
Tailstock Spindle Bore Taper: MT3
Thread Indicator: Yes
Thread Feeding:
SAE: 4 - 112 TPI, Total 40 Setting
Metric: 0.25 - 7.5 mm, Total 19 Setting
Net Weight: 838 lb.
(5) Hex Wrenches (3, 4, 5, 6, 8 mm) (1) Screwdriver (1) Oil Gun (5) Changing Gears: T30, T32, T40 (2
pcs), T127/120 (1) Face Plate 9-3/4” (1) Splash Guard (1) Oil Tray
(1) Steady Rest (1) Follow Rest (2) Dead Center: #3 (1) Center Sleeve: #5 / 3 (1) Live Center: MT3 (1) 6” 4-Jaw Chuck (1) Back Plate for 4-Jaw Chuck (1) Tool Post Wrench (1) Double End Wrenches 13-16
You will need the manual for the safety warnings and cautions, assembly instructions, oper­ating procedures, maintenance procedures, trouble shooting, parts list, and diagram. Keep your invoice with this manual. Write the invoice number on the inside of the front cover. Keep both this manual and your invoice in a safe, dry place for future reference.
READ ALL INSTRUCTIONS BEFORE USING THIS TOOL!
The Warnings, Cautions, and Instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be sup­plied by the operator.
For technical questions, please call 1-800-444-3353.
SAVE THIS MANUAL
ACCESSORIES
NOTICE
REV 02/07
Page 2SKU 43681
SAFETY WARNING & CAUTIONS
READ ALL INSTRUCTIONS BEFORE USING THIS TOOL!
1.
2.
3.
4.
5.
6.
7.
KEEP WORK AREA CLEAN. Cluttered areas invite injuries.
OBSERVE WORK AREA CONDITIONS. Do not use tools in damp, wet, or poorly lit
locations. Don’t expose to rain. Keep work area well lit. Do not use electrically powered equipment in the presence of flammable gases or liquids.
KEEP CHILDREN AWAY. Children must never be allowed in the work area. Do not let them handle machines, tools, or equipment.
STORE IDLE EQUIPMENT. When not in use, tools must be locked up in a dry location to inhibit rust. Always lock up tools and keep out of reach of children.
DO NOT FORCE THE TOOL. It will do the job better and more safely at the rate for which it was intended. Do not use inappropriate attachments in an attempt to exceed the tool’s capacities.
USE THE RIGHT TOOL FOR THE JOB. Do not attempt to force a small tool or attach­ment to do the work of a larger industrial tool. There are certain applications for which this tool was designed. Do not modify this tool, and do not use this tool for a purpose for which it was not intended.
DRESS PROPERLY. Do not wear loose clothing or jewelry, as they can be caught in moving parts. Non-skid footwear is recommended. Wear restrictive hair covering to contain long hair. Always wear appropriate work clothing.
8.
9.
10.
11.
12.
USE EYE, EAR AND BREATHING PROTECTION. Always wear ANSI approved im­pact safety goggles if you are producing metal filings or wood chips. Wear an ANSI approved dust mask or respirator when working around metal, wood, and chemical dusts and mists. Use ANSI approved ear protection when working in a loud or noisy environment.
DO NOT ABUSE THE POWER CORD. Protect the power cord from damage, either from impacts, pulling or corrosive materials. Do not yank machine’s cord to disconnect it from the receptacle.
DO NOT OVERREACH. Keep proper footing and balance at all times. Do not reach over or across running machines.
MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for better and safer per­formance. Follow instructions for lubricating and changing accessories. Inspect power cord periodically and, if damaged, have it repaired by an authorized technician. Control handle and power switch must be kept clean, dry, and free from oil and grease at all times.
REMOVE ADJUSTING KEYS AND WRENCHES. Be sure that keys and adjusting wrenches are removed from the tool or machine work surface before operation.
For technical questions, please call 1-800-444-3353.
Page 3SKU 43681
13.
AVOID UNINTENTIONAL STARTING. Be sure that you are prepared to begin work before turning the start switch on.
14.
15.
16.
17.
STAY ALERT. Watch what you are doing. Do not operate this machine when you are tired.
DO NOT OPERATE THIS MACHINE WHILE UNDER THE INFLUENCE OF ALCOHOL, DRUGS, OR PRESCRIPTION MEDICINES.
CHECK FOR DAMAGED PARTS. Before using any tool, any part that appears damaged
should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment and binding of moving parts, any broken parts or mounting fixtures, and any other condition that may affect proper operation. Any part that is damaged should be properly repaired or replaced by a qualified technician. Do not use the tool if any switch does not turn on and off properly.
REPLACEMENT PARTS AND ACCESSORIES. When servicing, use only identical replacement parts intended for use with this tool. Replacement parts are available from Harbor Freight Tools. Use of any other parts will void the warranty.
SPECIAL WARNINGS WHEN USING THIS BENCH LATHE
Using this Bench Lathe may create special hazards.
Take particular care to safeguard yourself and those around you.
Electrical Safety. Never operate any tool if there is an electrical hazard. Never oper- ate an electrical tool in wet conditions. Never operate a tool with an improper electrical cord or extension cord. Never operate an electrical tool unless you are plugged into a properly grounded outlet, which which is protected by an appropriate circuit breaker.
Ejected Material. Use safe practices to avoid injury from ejected material. Because the lathe and the workpieces turn at high speed, there is a danger of being injured by materi­als that may be ejected. Always wear ANSI-certified eye protection. Never attempt to work on any item if it is not adequately held. Always stand to one side of the plane in which the materials are spinning, to avoid being hit if an item is ejected. Never allow bystanders to be in the proximity of the lathe while in operation.
Entanglement. Use extreme caution to prevent loose materials from being caught in the machine. Never operate this lathe with loose clothing, long hair, jewelry, or other items
which may become caught in the tools or workpieces. In case of entanglement, press the OFF switch immediately.
NOTICE: No list of warnings can be all inclusive. The operator must supply common sense, and operate this tool in a safe manner.
supplies 115 Volts at 60 Hz. We recommend you use a circuit
For technical questions, please call 1-800-444-3353.
Page 4SKU 43681
BASIC COMPONENTS AND FEATURES OF YOUR #43681 GAP BED LATHE
Reference Description
A Press Switch C Emergency Stop Control D Indicator Light
E Gear Box
F Direction Control G Speed Control A H Speed Control B
I Oil Gauge
J Chuck K Bedway L Tool Holder
M Tool Post Clamping Lever N Compound Slide O Steady Rest
P Tailstock Quill
Q Tailstock Clamping Lever R Tailstock
S Tailstock Handwheel
Parts references in this text:
When parts are identified with letters, please refer to the diagram on this page.
When parts are identified with numbers, refer to parts lists and diagrams starting on page 16.
Reference Description
T Tailstock Base U Lead Screw V Control Lever
W Thread Dial
X Half Nut Lever
Y Cross/Longitudinal Feed Lever Z Cross Slide Handwheel
AA Saddle Handwheel
BB
CC Change Gear Control A EE Change Gear Control B
FF Oil Tray
GG Power Cord
HH Leadscrew Chart KK Splash Guard
MM Chuck Protection Cover
Feedrod & Leadscrew Exchange Lever
For technical questions, please call 1-800-444-3353.
Page 5SKU 43681
UNPACKING, ASSEMBLY, AND SET UP.
Basic assembly and adjustment of your new lathe was completed before being shipped.
Final assembly and adjustments must be made before operating your new lathe.
First find a suitable location for your lathe.
1.
2.
3.
4.
WARNING: Consult a licensed electrician if you are not completely sure that your power
Complete Assembly.
You will have to assemble the lathe onto the oil tray (FF) and then onto a bench top (not included) or metal stand.
Please note: The bench top must be able to with­stand the weight of the Lathe (838 lb.) as well as the weight of the workpiece. Do not exceed the maximum weight capacity of 1320 lb. If you choose to use a metal stand with this Lathe, the only Stand that will fit with this Lathe is SKU 95647 (sold separately).
The floor or work table which you place your lathe on must be level, solid, and resistant to vibration.
Your lathe should be positioned in an area which is protected from the weather, especially water and moisture.
You should provide good light to work in, and adequate space to operate and maintain the machine, as well as to handle work materials which will be loaded in the machine.
You will need an appropriate power supply to operate the machine, which requires 220 V~, 60 Hz, single phase current, and must be protected by a suitable circuit breaker.
supply is correct and safe.
Fig.1 Mounting bolts in the headstock.Fig.1 Mounting bolts in the headstock.
Fig.2 Mounting bolts in the tailstock.Fig.2 Mounting bolts in the tailstock.
1.
2.
3.
4.
Check to be sure that the bench is level and stable on the shop floor. If you need to repair the floor, do it now to be sure you have a solid, level surface to mount the machine.
Once the work bench is positioned properly on a solid level floor, place the oil tray (FF) on the bench. Using the mounting holes on the oil tray (FF) as reference, drill match­ing 1/2” holes into the wood bench. Always check to make sure no obstructions are in the drilling path.
Place the angled iron levelers between the oil tray (FF) and the bench top. Check the level and position of the bench top again to be sure that when the Lathe is positioned on the bench and oil tray (FF) it will be level, solid and aligned with the mounting holes in the bench and tray.
Using a drill and other hardware (not included) bolt the work bench to the floor before putting Lathe on the workbench to keep the bench and Lathe in place during use.
For technical questions, please call 1-800-444-3353.
Page 6SKU 43681
HOISTING AND LEVELING THIS MACHINE
WARNING: DO NOT ATTEMPT TO LIFT THE LATHE BY YOURSELF. This tool weighs over 800 lb., and cannot be lifted safely by one or several strong men. Be sure this lathe is balanced on the hoist or lift you will use to move it before moving.
1.
2.
3.
4.
5.
6.
Before hoisting, lifting or moving this machine, move the tailstock and apron to the far right end of the bedway (away from the headstock) and lock them in place there. This will help to balance the overall mass of the machine near the center.
Use pads (not included) to protect the lathe from damage by the equipment used to hoist it.
Use a hydraulic lift, fork lift, or hoist to position the lathe onto the bench (or SKU 95647 Stand).
When the lathe is positioned on the oil tray and bench, align the mounting holes and drop in the mounting bolts.
Check the level of the machine. Using a spirit level, check to be sure that the bed of the lathe is level both horizontally and front to back. If there is any out of level, correct it now. Depending on your installation, use the angled iron levelers to adjust the machine into exact level front to back and side to side. Check both ends of the tool before being sat­isfied. Be sure the machine is level, positioned solidly, and is resistant to vibration.
Fasten the lathe to the bench and oil tray (FF) by inserting a bolt through a lock washer from the inside of the bench and upward through the oil tray and lathe. Fasten with a washer and nut. Repeat this for each of the four mounting holes in the headstock, and both mounting holes in the tailstock. Tighten securely. Recheck and readjust level if required.
Note: Periodically recheck the level of the machine to ensure that it remains level while in use.
630
605
1704
460
Figure 3. Overall dimensions of this ma­chine, and oil tray dimensions. Dimensions are given in millimeters. Measure your own machine for any variations before using these dimensions.
For technical questions, please call 1-800-444-3353.
Page 7SKU 43681
THE HEADSTOCK
The headstock includes a Gear box (E) which con­tains gears and a belt drive. The gears are con­trolled by controls (F), (G), and (H). The belt drive transmits the motor power to the drive system of the machine.
1.
2.
3.
4.
The motor and drive belt are installed and ad­justed when delivered. However, you should check the adjustment of the drive belt before using this lathe.
Check the belt tension by pressing in the middle with your finger. You should be able to depress it approximately 1/2 inch. If the belt is too tight, it will wear the bearings, and if too loose, it will slip on the pulleys and wear out prematurely.
If it is necessary to adjust the belt tension, do so by adjusting the bolt and locknut assembly on the underside of the motor. The motor mounted on the back of the headstock.
Four additional change gears are included for use in cutting metric and SAE threads. Refer to the lead screw chart on the headstock for the gears required for the thread pitches you want. Please refer to the section on threading for more information.
Fig.4 Inside the Gear Box.
Fig.5 Motor mount and adjustment.
Fig.6 Headstock Controls.
For technical questions, please call 1-800-444-3353.
Page 8SKU 43681
SPEED AND POWER CONTROLS
Fig.7 Power Switch.
Fig.7 Power Switch.
You can turn lathe on and off and control speed and direction from the main control panel.
The Power Switch
1.
2.
3.
Speed and Direction Controls
Note: Do not change the settings of these controls if the motor is running. Shut OFF the power before changing these settings.
Quick Change Gearbox
The headstock is equipped with a quick change gearbox to control the rate of the spindle to the lead screw and feed rod, when it is used to cut threads, or for turning or facing.
Turn the Emergency Stop Switch (C) clockwise; the Indicator Light (D) will light up. The Spindle will not turn without operating the Control Lever (V).
The Press Switch (A) is used to run the spindle temporarily to allow the gears to engage when changing speed gears. When you release the switch, the spindle will stop.
In an emergency, you can stop the machine by pressing the Emergency Stop Control (C).
Fig.7 Power Switch.
Fig.7 Power Switch.
The Spindle Speed can be controlled by setting the Speed Control knobs (G) and (H). Refer to the chart on the Headstock to the right of the knobs to determine the proper setting for the desired spindle rotation speed. Eighteen speeds are possible from 72 to 1600 RPM. The direction may be controlled using Direction Control (F).
1.
2.
3.
Controls (CC) and (EE) may be used in combination to control the feed rate. Please refer to the lead screw chart (HH) for the desired setting.
The change gears may need to be re­placed to achieve the correct setting. Be sure the machine is turned off and is unplugged from its power supply before replacing the gears. Select the gears required from the lead screw chart.
When the Exchange Lever (BB) is in the middle position, the Lead Screw (118) and Feeding Rod (107) are locked. When Exchange Lever (BB) is to the right, the Lead Screw (118) is running and the machine can be used to turn the threads. When Exchange Lever (BB) is to the left, the Feeding Rod is running and the machine can be used set for automatic feeding.
Fig.8 Lead Screw Chart.
Fig.8 Lead Screw Chart.
4.
The half nut is engaged or disengaged using the Half Nut Lever (X). Note that the half nut must be engaged for the lead screw to function properly.
For technical questions, please call 1-800-444-3353.
Page 9SKU 43681
APRON The function of the Apron is to support the toolpost, and to be carried along the workpiece by the lead screw.
1.
2.
3.
4.
Use the Control Lever (V) to start the mo­tion of the Spindle, and to rotate it forward or reverse.
To operate the lever, push it toward the headstock, then move it up or down. Mov­ing the lever down will cause the spindle to rotate forward, moving it up will cause the spindle to rotate in reverse. Placing the lever in the middle will cause the spindle not to rotate.
The Half Nut Lever (X) for engaging the lead screw is mounted on the right side of the apron.
The Half Nut Lever (X) is used to engage or remove the half nut from the lead screw. This lever is mounted on the front of the apron. Engage the half nut only when mov­ing the apron in a longitudinal direction along the workpiece.
Fig.9 The Apron.Fig.9 The Apron.
5.
6.
7.
8.
The Cross/Longitudinal Feed Lever (Y) is used to determine the direction of travel of the tool on the workpiece. With the lever up, and the gear engaged, the apron will travel in a longitudinal direction along the workpiece; for example when threading. With the lever down, and the half nut disengaged, the tool post will travel horizontally across the workpiece; for example when face cutting.
Note: The interlock will prevent the half nut from being engaged when the Feed Lever (Y) is down in the cross feed position.
For threading, put the Feed rod & Leadscrew Exchange Lever (BB) to the right to start the lead screw, then move the Cross/Longitudinal Feed Lever (Y) to the center, and engage the half nut, using the Half Nut Lever (X). This will cause the lead screw to rotate, and the apron to move to the right.
You can also control the direction of travel of the apron using the Direction Control (F). Rotating this control to the right will cause the carriage to move to the right. Rotating this control to the left will cause the apron to move to the left.
For technical questions, please call 1-800-444-3353.
Page 10SKU 43681
THE THREADING DIAL
When the threads on the lead screw and on the workpiece are not in an integer ratio, it is necessary to use the thread­ing dial to control successive cuts. Determine this ratio by
dividing the desired TPI of the workpiece (for example 24 TPI) by the thread pitch of the lead screw (8 TPI). This example results in an integer ratio of 3:1. A desired thread pitch of 26 TPI (for example) on the workpiece would require use of the threading dial.
1.
2.
3.
4.
5.
6.
7.
8.
When the threads on the workpiece are not in an in­teger proportion to the threads on the lead screw, it is necessary to operate the half nut intermittently. This is controlled by using the threading dial. The Threading Dial (W) is located on the right side of the apron. The dial is marked with four numbered lines, 1, 2, 3, and 4. Between each numbered line is an unnumbered line. On the dial there is also a fixed reference line. When the threading dial is engaged with the lead screw, the dial will rotate. There is an instruction plate attached to the threading dial explaining the use of the dial, depending on the specific thread you are cutting. For thread cutting, engage the half nut at the appropriate numbers shown on the thread­ing dial. 1-4 means the half nut can be engaged at any of the numbered lines 1, 2, 3, or 4. For successive cuts, only numbered lines must be used. 1-3 / 2-4 on the scale means that the half nut can only be engaged on 1 and 3 or 2 and 4 for successive cuts. For example, if you engage the half nut on “1” on the first cut, you can only engage it on “1” or “3” on following cuts. If you engage it on “2” on the first cut, you can only engage it on “2” and “4” on successive cuts. 1-8 means the half nut cannot be engaged on any lines, numbered or unnumbered. If the half-nut is engaged throughout the initial cut, there is no need to use the thread­ing dial. Simply disengage the half nut, back the tool to the starting point, reengage the half nut and start over.
Fig.10 Threading Dial.Fig.10 Threading Dial.
FOUR-POSITION TOOL REST The four position tool rest can be used to hold up to four tools. It is controlled by the three handwheels on the Apron, the Saddle Handwheel (AA), the Cross Slide Handwheel (Z) and the Compound Slide Handwheel (N).
1.
2.
3.
Tools are held in place on each side of the tool holder by two or three of the bolts on that side. Tools must fit into the tool groove. When installing tools, check to see that the cutting edge is properly aligned with the rotating direction of the workpiece. The tool post can be rotated by loosening the Tool Post Clamping Lever (M), rotating the tool post, and retightening the lever.
For technical questions, please call 1-800-444-3353.
Fig.11 Tool Post.Fig.11 Tool Post.
Page 11SKU 43681
COMPOUND SLIDE The tool is moved along the workpiece by the motion of the apron and its compo­nents. The apron may be power-driven by the lead screw, or may be moved by hand using the handwheels.
1.
2.
3.
4.
5.
This lathe may be operated using either chuck or faceplate to hold the workpiece.
The Saddle Handwheel (AA) may be used to move the apron with its attached tool post and tools along the rotating axis of the workpiece. This is used to make longitudinal cuts.
The Cross Slide Handwheel (Z) is used to move the tool post horizontally across the axis of the workpiece. This motion is used to make face cuts at a 90 degree angle to the longitudinal axis of the workpiece.
Cuts made at any angle other than 90 degrees to the axis are accomplished by using the Compound Slide Handwheel (N).
To use the compound slide, loosen the bolt holding it in place on the cross-slide, rotate it into the desired position, then retighten the bolt.
The cutting tool can be moved into the workpiece by operating the handwheel.
CHUCK AND FACEPLATE
Fig.12 Compound Slide.Fig.12 Compound Slide.
1.
2.
3.
4.
Chucks and faceplates are mounted on the arbor shaft using a threaded connection. Open the gear box, and using a suitable wrench, hold back the arbor shaft to prevent it from turning. Grip the chuck or faceplate, and rotate it in a counter-clockwise direction to unthread it from the arbor shaft.
When re-installing a chuck or faceplate, be sure to put light grease on the threaded end of the arbor shaft to ease installation and removal of the chuck or faceplate.
You are provided with both three and four jaw chucks. Each may be used to hold workpieces by clamping from the outside, or by expanding on the inside of tubes and hollow pieces. To tighten the jaws, rotate any of the internal hex head bolts in the side of the chuck with an appropriate size hex wrench. Chucks are self centering, and will align concentric workpieces with the axis of rotation of the arbor shaft.
Faceplates are used typically to hold larger or non-round pieces. Work pieces may be attached to the faceplate by a variety of methods including clamps, bolts and screws. It is critical that the centerpoint of the workpiece be exactly aligned with the center of rotation of the arbor shaft for accurate turning.
Fig.13 Chuck.Fig.13 Chuck.
For technical questions, please call 1-800-444-3353.
Page 12SKU 43681
TAILSTOCK The tailstock slides along the bed way freely, and may be used to secure the free end of a rotating workpiece.
1.
2.
3.
4.
5.
The tailstock is clamped to the bedway using the Tailstock Clamping Lever (Q). The Quill (P) can be rotated inward and outward, using the Tailstock Handwheel (S). The Quill can be locked in place using the Quill Lock Lever. The quill is shipped with a “dead end” which may be inserted into the quill. “Dead end” means that the end remains stationary, and allows the workpiece to rotate upon it. To reduce friction, it is a good idea to apply a little grease to the
Fig.14 Tailstock.
contact between the workpiece and the dead end. Check this lubrication from time to time. “Live ends” are available to fit this machine and may be purchased separately. Live ends incorporate a bearing to reduce friction between the workpiece and the quill. Before using your lathe, it is important to check the alignment of the tailstock with the arbor spindle. Do this by placing a precisely machined rod in the chuck, and checking its alignment with the center of the quill. Accurate measurements may be made by mounting a dial indicator to the bedway, and making measure­ments on the rod near the headstock, and near the tailstock. These measurements must be exactly alike for the tailstock to be properly aligned. Adjustments may be made by loosening the tailstock lock lever, then adjusting the position of the tailstock with the alignment screw (512). Retighten the lock lever, and recheck the alignment before proceeding.
Fig.14 Tailstock.
Fig.15 Follow Rest.
Fig.15 Follow Rest.
FOLLOW REST AND STEADY REST
These are useful supports for your workpiece, which help you improve machining accuracy.
1.
2.
3.
4.
5.
The Follow Rest is attached to the Apron, and fol­lows the movement of the apron as the workpiece is machined. The Steady Rest is attached to the bedway, and re­mains in place as the workpiece turns within it. Install these rests as needed to support the work­piece. Adjust the brass holders within the rests to lightly ride upon the workpieces. It is advisable to apply a little grease to the points of the brass holders to reduce friction between them and the workpiece. The rests should be cleaned and stored in a dry clean place when not in use.
For technical questions, please call 1-800-444-3353.
Fig.16 Steady Rest.Fig.16 Steady Rest.
Page 13SKU 43681
Loading...
+ 28 hidden pages