OPTIMUM
MASCHINEN - GERMANY
Operating manual
Version 1.0.1
Lathe
GB
OPTIMUM
MASCHINEN - GERMANY
Table of contents
1 Safety
1.1 Safety warnings (warning notes) ..............................................................................................................8
1.1.1 Classification of hazards............................. ..............................................................................................8
1.1.2 Other pictograms......................................................................................................................................9
1.2 Intended use.............................................................................................................................................9
1.3 Reasonably foreseeable misuse.............................................................................................................10
1.3.1 Avoiding misuse.......................................... ..................................................... ... ....................................10
1.4 Possible dangers caused by the machine ..............................................................................................10
1.5 Qualification of the staff..........................................................................................................................11
1.5.1 Target group...........................................................................................................................................11
1.5.2 Authorized persons.................................................................................................................................12
1.5.3 Obligations of the operating company....................................................................................................12
1.5.4 Obligations of the operator .....................................................................................................................12
1.5.5 Additional requirements regarding the qualification................................................................................12
1.6 Operator positions ..................................................................................................................................12
1.7 Safety measures during operation..........................................................................................................13
1.8 Safety devices ........................................................................................................................................13
1.9 EMERGENCY-STOP button.......................................... ... ..................................................... ... ..............14
1.9.1 Lockable main switch (only TU 2506V, TU2807V) .................................................................................15
1.9.2 Protective cover with safety switch.........................................................................................................15
1.9.3 Lathe chuck protection with position switch............................................................................................15
1.9.4 Lathe chuck key......................................................................................................................................16
1.10 Safety check...........................................................................................................................................16
1.11 Personnel protective equipment .............................................................................................................17
1.12 For your own safety during operation.....................................................................................................17
1.13 Disconnecting and securing the lathe.....................................................................................................17
1.14 Using lifting equipment ...........................................................................................................................18
1.15 Mechanical maintenance work ...............................................................................................................18
2 Technical data
2.1 Electrical connection...............................................................................................................................19
2.2 Machine data..........................................................................................................................................19
2.3 Working area ......................................................... .................................................................................19
2.6 Emissions ...............................................................................................................................................20
2.4 Environmental conditions.................................... ... ..................................................... ... .........................20
2.5 Operating material..................................................................................................................................20
2.7 Dimensions, installation plan TU2506 ....................................................................................................21
2.8 Dimensions, installation plan TU2506V..................................................................................................22
2.9 Dimensions, installation plan TU2807 ....................................................................................................23
2.10 Dimensions, installation plan TU2807V..................................................................................................24
2.11 Distance between centres, height of centres TU2506, TU2506V...........................................................25
2.12 Distance between centres, height of centres TU2807, TU2807V...........................................................26
3 Assembly
3.1 Scope of delivery....................................................................................................................................27
3.2 Transport ................................................................................................................................................27
3.3 Storage...................................................................................................................................................28
3.4 Installation and assembly .......................................................................................................................29
3.4.1 Requirements to the installation site.......................................................................................................29
3.4.2 Load suspension point............................. ... ... ..................................................... ... .................................29
3.4.3 Installation...............................................................................................................................................29
3.5 Assembly of the synchronous belt and V-belt on the lathe.....................................................................30
3.5.1 Assembly of the synchronous belt on the lathe TU 2506, TU 2807, TU2807 V .....................................30
3.5.2 Assembly of the synchronous belt on the lathe TU 2506 V....................................................................30
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MASCHINEN - GERMANY
3.5.3 Assembly of the V-belt on the lathe........................................................................................................31
3.6 First commissioning................................................................................................................................31
3.6.1 Warming up the machine ......................................................................................................................31
3.6.2 Cleaning and lubricating.........................................................................................................................31
3.6.3 Visual inspection ........................................ ... ..................................................... ... ... ..............................32
3.6.4 Functional test............................................... .........................................................................................32
3.6.5 Electrical connection ..............................................................................................................................32
3.6.6 Functional check ...................................................................................................... .. .. ..........................33
3.7 Optional machine accessories ...............................................................................................................33
3.8 Mounting instruction ...............................................................................................................................34
3.8.1 Mounting instruction chuck flange..........................................................................................................34
3.8.2 Flange for the lathe chuck......................................................................................................................35
3.8.3 Mounting instruction of collet chuck holder ............................................................................................36
3.8.4 Mounting of follow rest TU 2506 (V).......................................................................................................37
3.8.5 Mounting of follow rest TU 2807 (V).......................................................................................................37
3.8.6 Mounting of steady rest TU 2506 (V) .....................................................................................................38
3.8.7 Mounting of steady rest TU 2807 (V) .....................................................................................................38
4Operation
4.1 Operation TU2506 and TU2807.............................................................................................................39
4.1.1 Control and indicating elements.............................................................................................................39
4.1.2 Switching elements ......................................................................................... ... ....................................40
4.1.3 Switching on the machine ......................................................................................................................40
4.1.4 Switching off the machine ......................................................................................................................40
4.2 Operation TU2506V ........................................................................................... ... .................................41
4.2.1 Control and indicating elements.............................................................................................................41
4.2.2 Switching elements ......................................................................................... ... ....................................42
4.2.3 Switching on the machine ......................................................................................................................42
4.2.4 Switching off the machine ......................................................................................................................42
4.3 Operation TU2807V ........................................................................................... ... .................................43
4.3.1 Control and indicating elements.............................................................................................................43
4.3.2 Switching elements ......................................................................................... ... ....................................44
4.3.3 Switching on the machine ......................................................................................................................44
4.3.4 Switching off the machine ......................................................................................................................44
4.4 Safety.....................................................................................................................................................45
4.5 Operating elements for feed...................................................................................................................45
4.6 Tool holder .............................................................................................................................................45
4.7 Lathe chuck............................................................................................................................................46
4.7.1 Replacing the clamping jaws on the lathe chuck....................................................................................46
4.8 Speed adjustment ..................................................................................................................................47
4.8.1 Changing the speed range.....................................................................................................................48
4.8.2 Speed table TU 2506 .............................................................................................................................48
4.8.3 Speed table TU 2506V...........................................................................................................................49
4.8.4 Speed table TU2807 ..............................................................................................................................49
4.8.5 Speed table TU 2807V...........................................................................................................................49
4.9 Feed adjustment.....................................................................................................................................50
4.9.1 Selector switch.......................................................................................................................................50
4.9.2 Changing the change gears ...................................................................................................................50
4.9.3 Arrangement of change gears................................................................................................................51
4.9.4 Tables for thread-cutting........................................................................................................................52
4.9.5 Transmission ratio..................................................................................................................................52
4
.9.6 Example - assembly of gear wheels for thread 0.75mm 1.5mm 3mm ...................................................53
4.10 Feed engaging lever...............................................................................................................................53
4.11 Fixing the lathe saddle ...........................................................................................................................54
4.12 Turning tapers................................................................................... ... ..................................................55
4.12.1 Turning short tapers with the to p slide ...................................................................................................55
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MASCHINEN - GERMANY
4.12.2 Turning tapers with the tailstock .............................................................................................................55
4.12.3 Turning of cones with high precision ......................................................................................................56
4.13 Tailstock sleeve......................................................................................................................................59
4.14 Clamping a workpiece into the three jaw chuck......................................................................................59
4.15 Standard values for cutting data when turning .......................................................................................60
4.16 Cutting speed table.................................................................................................................................61
4.17 Terms for the rotating tool.......................................................................................................................62
4.17.1 Cutting edge geometry for turning tools..................................................................................................63
4.17.2 Types of cutting form levels....................................................................................................................63
4.18 Tapping of external and internal threads ................................................................................................65
4.19 Thread types...........................................................................................................................................67
4.19.1 Metric threads (60° flank angle)..............................................................................................................68
4.19.2 British thread (55° flank angle) ...............................................................................................................70
4.19.3 Indexable inserts.....................................................................................................................................71
4.19.4 Examples for thread cutting....................................................................................................................72
4.20 Recessing, cutting off and turning off .....................................................................................................74
5 Maintenance
5.1 Safety......................................................................................................................................................76
5.1.1 Preparation.............................................................................................................................................76
5.1.2 Restarting ...............................................................................................................................................76
5.2 Inspection and maintenance...................................................................................................................77
5.3 Repair.....................................................................................................................................................79
6 Ersatzteile - Spare parts TU2807 | TU2807V
6.1 Oberschlitten - Top slide .........................................................................................................................80
6.2 Planschlitten- Cross slide .......................................................................................................................81
6.3 Bettschlitten - Bed slide..........................................................................................................................82
6.4 Reitstock 2 - Tailstock 2..........................................................................................................................83
6.5 Maschinenbett - Machine bed.................................................................................................................84
6.6 Vorschubgetriebe 1 von 2 - Feed gear 1 of 2.........................................................................................85
6.7 Vorschubgetriebe 2 von 2 - Feed gear 2 of 2.........................................................................................86
6.8 Spindelstock 1 von 2 - Headstock 1 of 2................................................................................................87
6.9 Spindelstock 2 von 2 - Headstock 2 of 2................................................................................................88
6.10 Spindelstock - Headstock TU 2807 V..................................................................................................... 89
6.11 Wechselradgetriebe - Change gear........................................................................................................90
6.12 Ersatzteilliste - Spare parts list TU 2807.................................................................................................91
6.12.1 Ersatzteilliste TU 2807 V - Spar e parts list TU 2807 V...........................................................................96
6.13 Maschinenschilder - Machine labels TU 2807........................................................................................97
6.13.1 Maschinenschilder - Machine labels TU 280 7 ........................................................................................97
6.14 Maschinenschilder - Machine labels TU 2807 V.....................................................................................98
6.14.1 Maschinenschilder - Machine labels TU 280 7 V.....................................................................................98
7 Ersatzteile - Spare parts TU2506 | TU2506V
7.1 Oberschlitten - Top slide .........................................................................................................................99
7.2 Planschlitten- Cross slide .....................................................................................................................100
7.3 Bettschlitten - Bed slide........................................................................................................................101
7.4 Ersatzteilzeichnung Reitstock - Tailstock .............................................................................................102
7.5 Maschinenbett - Machine bed...............................................................................................................103
7.6 Vorschubgetriebe 1 von 2 - Feed gear 1 of 2.......................................................................................104
7.7 Vorschubgetriebe 2 von 2 - Feed gear 2 of 2.......................................................................................105
7.8 Spindelstock 1 von 2 - Headstock 1 of 2..............................................................................................106
7.9 Spindelstock 2 von 2 - Headstock 2 of 2..............................................................................................107
7.10 Spindelstock - Headstock TU 2506 V...................................................................................................108
7.11 Wechselradgetriebe - Change gear......................................................................................................109
7.12 Ersatzteilliste - Spare parts list TU2506................................................................................................110
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MASCHINEN - GERMANY
7.12.1 Ersatzteilliste TU 2506 V - Spare parts list TU 2506 V.........................................................................116
7.13 Maschinenschilder - Machine labels TU 2506......................................................................................117
7.13.1 Maschinenschilder - Machine labels TU 2506......................................................................................117
7.14 Maschinenschilder - Machine labels TU 2506 V ..................................................................................118
7.14.1 Maschinenschilder - Machine labels TU2506V....................................................................................118
8 Malfunctions
9 Schaltpläne - Wiring diag rams
9.1 Schaltplan - Wiring diagram TU 2506 - 230V ......................................................................................120
9.2 Schaltplan - Wiring diagram TU 2506 / TU 2807 - 400V......................................................................121
9.3 Schaltplan - Wiring diagram TU 2506 V / TU 2807 V...........................................................................122
10 Appendix
10.1 Copyright..............................................................................................................................................123
10.2 Terminology/Glossary ..........................................................................................................................123
10.3 Change information operating manual .................................................................................................123
10.4 Product follow-up..................................................................................................................................124
10.5 Liability claims for defects / warranty....................................................................................................125
10.6 Note regarding disposal / options to reuse:..........................................................................................125
10.6.1 Decommissioning.................................................................................................................................126
10.6.2 Disposal of the packaging of new devices ...........................................................................................126
10.6.3 Disposing of the old device ..................................................................................................................126
10.6.4 Disposal of electrical and electronic components ................................................................................126
10.6.5 Disposal of lubricants and coolants......................................................................................................127
10.7 Disposal via municipal collection..........................................................................................................127
10.8 RoHS , 2002/95/CE..............................................................................................................................127
10.9 EC Declaration of Conformity TU2506.................................................................................................128
10.10 EC Declaration of Conformity TU2807.................................................................................................129
10.11 EC Declaration of Conformity TU2506V...............................................................................................130
10.12 EC Declaration of Conformity TU2807V...............................................................................................131
TU2506 | TU2506V | TU2807 | TU2807V GB
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OPTIMUM
MASCHINEN - GERMANY
Preface
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 product innovations guarantee
state-of-the-art products and safety at any time.
Before commissioning the machine please thoroughly read these operating instructions and get familiar with
the machine. Please also make sure that all persons operating the machine have read and understood the
operating instructions beforehand.
Keep these operating instructions in a safe place nearby the machine.
Information
The operating instructions include indications for safety-relevant and proper installation, operation and maintenance of the machine. The continuous observance of all notes included in this manual guarantee the safety
of persons and of the machine.
The manual determines the intended use of the machine and includes all necessary information for its economic operation as well as its long service life.
In the paragraph "Maintenance" all maintenance works and functional tests are described which the operator
must perform in regular intervals.
The illustration and information included in the present manual can possibly deviate from the current state of
construction of your machine. Being the manufacturer we are continuously seeking for improvements and
renewal of the products. Therefore, changes might be performed without prior notice. The illustrations of the
machine may be different from the illustrations in these instructions with regard to a few details. However, this
does not have any influence on the operability of the machine.
Therefore, no claims may be derived from the indications and descriptions. Changes and errors are r eserved!
Your suggestion with regard to these operating instructions are an important contribution to optimisi ng our
work which we offer to our customers. For any questions or suggestions for improvement, please do not hesitate to contact our service department.
If you have any further questions after reading these operating instructions and you are not able to solve your
problem with a help of these operating instructions, please contact your specialised dealer or directly the
company OPTIMUM.
Optimum Maschinen Germany GmbH
Dr.- Robert - Pfleger - Str. 26
D-96103 Hallstadt
Mail: info@optimum-maschinen.de
Internet: www.optimum-maschinen.com
TU2506 | TU2506V | TU2807 | TU2807VGB
Version 1.0.1 2013-10-31Page 6 Original operating instructions
1 Safety
Glossary of symbols
OPTIMUM
MASCHINEN - GERMANY
This part of the operating manual
In addition to this operating manual, please note
European standards must be kept during installation, operation, maintenance and repair of the
lathe.
If European standards are not applied at the national legislation of the country of destination,
the specific applicable regulations of each country are to be observed.
If necessary, the required measures must be taken to comply with the specific regulations of
each country before the lathe is used for the first time.
gives further advice
calls on you to act
enumeration
does explain the meaning and how to use the warning references contained in this operating manual,
defines the intended use of the lathe,
points out the dangers that might arise for you or others if these instructions are not observed,
informs you about how to avoid dangers.
the applicable laws and regulations,
the legal regulations for accident prevention.
the prohibition, warning and mandatory signs as well as the
warning notes on the lathe.
ALWAYS KEEP THIS DOCUMENTATION CLOSE TO THE LATHE.
INFORMATION
If you are unable to solve a proble m 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
Version 1.0.1 2013-10-31 Page 7Original operating instructions
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OPTIMUM
MASCHINEN - GERMANY
1.1 Safety warnings (warning notes)
1.1.1 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
DANGER!
WARNING!
CAUTION!
ATTENTION!
INFORMATION
In case of specific dangers, we replace the pictogram by
Threatening danger that will cause serious injury or death to people.
A danger that might cause severe injury to the staff or can lead to death.
Danger or unsafe procedure that might cause injury to people or damage
to property.
Situation that could cause damage to the machine and product and other
types of damage.
No risk of injury to people.
Application tips and other important or useful information and notes.
No dangerous or harmful consequences for people or objects.
or
general danger with a warning of injuries to hands, hazardous electri-
cal voltage,
rotating parts.
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Safety
1.1.2 Other pictograms
OPTIMUM
MASCHINEN - GERMANY
Caution slide risk! Activation forbidden! Pull the main plug! Use safety glasses!
protection
Use protective
gloves!
Use protective
boots!
Wear a safety suit! Protect the environ-
ment!
Use ear protection!
Contact address
1.2 Intended use
WARNING!
In the event of improper use, the lathe
will endanger personnel,
will endanger the machine and other material property of the operator,
the correct function of the machine may be affected.
The machine is designed and manufactured to be used in environments where there is no potential danger of explosion.
The lathe is designed and manufactured for straight turning and facing round and regular
formed three-, six- or twelve-square workpieces in cold metal, castings and plastics or similar
materials that do not constitute a health hazard or do not create dust, such as wood, Teflon®.
The lathe must only be installed and operated in a dry and ventilated place. The clamping
workpieces in the feed may only be effected with the supplied the special key for chucks.
If the lathe is used in any way other than described above, modified without authorization of
Optimum Maschinen Germany GmbH, then the lathe is being used improperly.
We do not take liability for damage caused through improper use.
We would like to stress that any modifications to the construction, or technical or technological
modifications that have not been authorized by Optimum Maschinen Germany GmbH will also
render the guarantee null and void.
It is also part of proper use that
the operating manual is constantly observed,
inspection and maintenance instruct ion s ar e ob se rve d .
observe the limits of the lathe,
"Technical data“ on page 19
In order to achieve optimum cutting performance, it is essential to choose the right turning tool,
feed, tool pressure, cutting speed and coolant.
"Standard values for cutting data when turning“ on page 60
Safety
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OPTIMUM
MASCHINEN - GERMANY
WARNING!
Very serious injury due to improper use.
It is forbidden to make any modifications or alternations to the operation values of the
lathe. They could endanger employees and cause damage to the lathe.
INFORMATION
The TU2506V and TU2807V is built according to the standard DIN EN 55011 class A.
WARNING!
The class A (machine tools) is not intended to be used in residential facilities, where the
power is supplied via a public low voltage supply system. In these areas it may possibly
be difficult to guarantee electromagnetic compatibility due to lead bound aswell a s
emitted interferences.
ATTENTION!
If the lathe is not used as intended or if the safety directives or the operat ing instruc tions
are ignored the liability of the manufacturer for any damages to persons or objects
resulting hereof is excluded and the claim under guarantee is becoming null and void!
1.3 Reasonably foreseeable misuse
Any other use as the one determined under the "Intended use" or any use beyond the
described use shall be deemed as not in conformity and is forbidden.
If it is intended to use the device in any other wa y as de sc rib ed ab ov e, it is nec e ssa ry to con su lt
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.
1.3.1 Avoiding misuse
Using suitable cutting tools.
Adapting speed settings and feed on the material and on the workpiece.
Clamp the workpiece firmly and vibration-free.
1.4 Possible dangers caused by the machine
The lathe has undergone a safety inspection (analysis of danger with assessment of risks). It
has been designed and built on the basis of this analysis using the latest technological advances.
Nonetheless, there remains a residual risk, since the machine operates with
high revolutions,
rotating parts,
with electrical voltages and currents.
We have used construction resources and safety techniques to minimize the health risk to persons resulting from these hazards.
If the lathe is used and maintained by th e staff who are not duly qualified, there ma y be a risk
resulting from incorrect or unsuitable main te na nc e of the lat he .
INFORMATION
All staff involved in assembly, commissioning, operation and maintenance, must
TU2506 | TU2506V | TU2807 | TU2807VGB
Safety
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MASCHINEN - GERMANY
be duly qualified,
strictly follow this operating manual.
Always disconnect the machine if cleaning or maintenance work is being carried out.
WARNING !
The lathe may only be used with the safety devices activated.
Disconnect the lathe immediately whenever you detect a failure in the safety devices or
when they are not mounted!
All additional installations carried out by the operator must incorporate the prescribed
safety devices.
This is your responsibility being the operating company!
"Safety measures during operation“ on page 13
1.5 Qualification of the staff
1.5.1 Target group
This manual is addressed to
the operating companies,
the users,
the staff for maintenance works.
Therefore, the warning notes refer to both operation and maintenance of the machin e.
Always disconnect the machine plug from the mains. This will prevent it from being used by un-
authorized persons.
INFORMATION
All staff involved in assembly, commissioning, operation and maintenance, mus t
be duly qualified,
strictly follow this operating manual.
In the event of intended use
there is a risk for the employee,
the lathe and further property might be endangered,
the correct function of the lathe may be affected.
The qualifications of the staff for the different tasks are mentioned below:
Operator
The operator is instructed by the operating company about the assigned tasks and possible
risks in case of improper behaviour. Any tasks which need to be performed beyond the operation in the standard mode must only be performed by the operator if it is indicated in these
instructions and if the operating company expressively commissioned the operator.
Electrical specialist
Due to his professional training, knowledge and experience as well as his knowledge of respective standards and regulations the electrical specialist is able to perform works on the electrical
system and to recognise and avoid any possible dangers himself.
The electrical specialist is specially trained for the working environment in which he is working
and knows the relevant standards and regulations.
Safety
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OPTIMUM
MASCHINEN - GERMANY
Specialist staff
Due to his professional training, knowledge and experience as well as his knowledge of relevant regulations the specialist staff is able to perform the assigned tasks and to recognise and
avoid any possible dangers himself.
Instructed persons
Instructed persons were instructed by the operating company about the assigned tasks and any
possible risks in case of improper behaviour.
1.5.2 Authorized persons
WARNING!
Inappropriate operation and maintenance of the machine constitutes a danger for the
staff, objects and the environment.
Only authorized staff may operate the machine!
Persons authorized to operate and maintain should be trained technical staff and instructed by
the ones who are working for the operating company and for the manufacturer.
1.5.3 Obligations of the operating company
The operator must instruct the staff at least once per year regarding
all safety standards that apply to the machine.
the operation,
accredited technical guidelines.
The operator must also
check the knowledge of the staff,
document the trainings/instructions,
require staff to confirm participation in training/instructions by means of a signature,
check if the staff is aware of safety rules and dangers in the workplace and that they ob-
serve the operating manual.
1.5.4 Obligations of the operator
The operator must
have read and understood the operating manual,
be familiar with all safety devices and regulations,
be able to operate the machine.
1.5.5 Additional requirements regarding the qualification
For work on electrical components or equipment, there are additional requirements:
Must only be performed by a qualified electrician or person working under the instructions
and supervision of a qualifiedelectrician.
Before carrying out work on electrical components or operating units, the following measures must be taken, in the order given.
disconnect all poles.
ensure that the lathe cannot be turned on again,
check that there is no voltage.
1.6 Operator positions
The operator’s position is in front of the machine.
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MASCHINEN - GERMANY
1.7 Safety measures during operation
CAUTION!
Risk due to inhaling of health hazardous dusts and mist.
Dependent on the material which need to be processed and the used auxiliaries dusts
and mist may be caused which might impair you health.
Make sure that the generated health hazardous dusts and mist are safely sucked off at
the point of origin and is dissipated or filtered from the working area. To do so, use a
suitable extraction unit.
CAUTION!
Risk of fire and explosion by using flammable materials or cooling lubricants.
Before processing inflammable materials (e.g. aluminium, magnesium) or using
inflammable auxiliary materials (e.g. spirit) it is necessary to take additional preventive
measures in order to safely avoid health risks.
CAUTION!
Risk of winding-up or cutting damages when using hand tools.
The machine is not designed for the use of hand tools (e.g. emery cloth or files). It is
forbidden to use any hand tools on this machine.
1.8 Safety devices
Use the lathe only with properly functioning safety devices.
Stop the lathe immediately if there is a failure on the safety device or if it is not functioning for
any reason.
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 persons or objects.
Safety
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OPTIMUM
EMERGENCY-
STOP button
TU 2506,
TU 2807
EMERGENCY-
STOP button
TU 2506 V,
TU 2807 V
MASCHINEN - GERMANY
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. The possible consequences are
injuries due to components or parts of components flying off at high speed,
contact with rotating parts,
fatal electrocution,
WARNING!
The separating protective equipment which is made available and delivered together
with the machine is designed to reduce the risk of workpieces or fractions of them which
being expelled, but not to remove them completely.
Always work carefully and observe the limits of their machining process.
The lathe includes the following safety devices:
a EMERGENCY STOP button
a protective cover on the headstock,
a special key for the lathe chuck,
a lathe chuck protection with position switch.
1.9 EMERGENCY-STOP button
The EMERGENCY-STOP button
switches the lathe off.
Knocking on the emergency stop device
triggers an emergency stop.
After actuating the switch, turn it to the
right, in order to restart the lathe.
TU2506 | TU2506V | TU2807 | TU2807VGB
Img.1-1: EMERGENCY-STOP button
Safety
Version 1.0.1 2013-10-31Page 14 Original operating instructions
1.9.1 Lockable main switch (only TU 2506V, TU2807V)
Main switch
integrated
position switch
Protective cover
Lathe chuck pro-
tection
closed
Lathe chuck pro-
tection
open
integrated
position switch
In the position "0", the lockable main
switch can be secured against accidental
or non-authorized switching-on by means
of a padlock.
When the main switch is switched off, the
power supply to the machine is completely interrupted.
1.9.2 Protective cover with safety switch
The headstock of the lathe is equipped
with a fixed, separating protective cover.
The locked position is monitored by
means of an electrical limit switch.
INFORMATION
It is not possible to start the machine until
the protective cover is closed.
OPTIMUM
MASCHINEN - GERMANY
Img.1-2: Lockable main switch
1.9.3 Lathe chuck protection with position switch
The lathe is provided with a lathe chuck
protection. The lathe can only be
switched on if the lathe chuck protection
is closed.
Img.1-3: for the protective cover of the headstock
Safety
Version 1.0.1 2013-10-31 Page 15Original operating instructions
Img.1-4: Lathe chuck protection
TU2506 | TU2506V | TU2807 | TU2807V GB
OPTIMUM
Safety lathe chuck
key
Lathe chuck key
MASCHINEN - GERMANY
1.9.4 Lathe chuck key
The lathe is equipped with a special key
for chucks. Once the lathe chuck key has
been released, it is pushed out of the
lathe chuck by a spring.
CAUTION!
Only operate the lathe using this key.
1.10 Safety check
Check the lathe regularly.
Check all safety devices
before starting work,
once a week,
after every maintenance and repair work.
Img.1-5: Lathe chuck key
General check
Equipment Check OK
Protective covers,
lathe chuck protection
Signs, markings installed and legible
Mounted, firmly bolted and not damaged
Functional check
Equipment Check OK
EMERGENCY-STOP button
Lathe chuck key Once the chuck key has been released, it should be automatically pressed
Lathe chuck protection /
protective cover headstock
When the EMERGENCY STOP push button is activated, the lathe must
switch off.
out of the lathe chuck.
The lathe shall only run with the lathe chuck protection / protective cover
headstock closed.
TU2506 | TU2506V | TU2807 | TU2807VGB
Safety
Version 1.0.1 2013-10-31Page 16 Original operating instructions
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1.11 Personnel protective equipment
For certain work personal protective equipment is required.
Protect your face and your eyes: Wear a safety helmet with facial protection when performing
works where your face and eyes are exposed to hazards.
Use protective gloves when handling pieces with sharp edges.
During operation of the lathe, the wearing of gloves is prohibited because of the risk of winding
up.
Use safety shoes when you assemble, disassemble or transport heavy components.
Use ear protection if the noise level (emission) in the workplace exceeds 80 dB (A).
Before starting work, make sure that the prescribed personal protective equipment is available
at the workplace.
CAUTION!
Dirty or contaminated personnel protective equipment can cause diseases.
Clean it each time after use and once a week.
1.12 For your own safety during operation
WARNING!
Before activating the machine assure yourself that this will neither endanger other
persons nor cause damage to equipment.
Avoid any risky working practices:
Make sure, your work does not endanger anyone.
Clamp the workpiece tightly before activating the lathe.
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.
Clamp the turning tool at the correct height and with the least possible overhang.
Turn off the lathe before measuring the workpiece.
The instructions mentioned in these operating instructions have to be strictly observed dur-
ing assembly, operation, maintenance and repair.
Do not work on the lathe, if your concentration is reduced, for example, because you are
taking medication.
Observe the accident prevention regulations issued by your Employers Liability Insurance
Association or other competent supervisory authority, responsible for your company.
Stay at the lathe until all movements have come to a complete standstill.
Use the prescribed personnel protective equipment. Make sure to wear a well-fitting work
suit and, if necessary, a hairnet.
We specially point out the specific dangers when working with and on the machine.
1.13 Disconnecting and securing the lathe
Pull the mains plug before beginning any maintenance or re pair work or or switch off the
supply voltage to the lathe. All machine components and hazardous voltages and move-
ments are disconnected.
Secure the machine using a padlock on the lockable main switch (only TU2506 / TU2807
Vario).
Attach a warning sign on the machine.
Safety
Version 1.0.1 2013-10-31 Page 17Original operating instructions
TU2506 | TU2506V | TU2807 | TU2807V GB
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MASCHINEN - GERMANY
1.14 Using lifting equipment
WARNING!
The use of unstable lifting and load suspension gear that might break under load can
cause severe injuries or even death.
Check that the lifting equipment and load-suspension gears are of sufficient load
capacity and are in perfect condition.
Observe the accident prevention regulations issued by your Employers Liability
Insurance Association or other competent supervisory authority, responsible for your
company.
Fasten the loads properly.
Never walk under suspended loads!
1.15 Mechanical maintenance work
Remove or install protection safety devices before starting any maintenance work and re-install
them once the work has been completed.This includes:
covers,
safety indications and warning signs,
earth (ground) connections.
If you remove protection or safety devices, refit them immediately after completing the work.
Check if they are working properly!
TU2506 | TU2506V | TU2807 | TU2807VGB
Version 1.0.1 2013-10-31Page 18 Original operating instructions
Safety
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MASCHINEN - GERMANY
2 Technical data
The following information are the dimensions and indications of weight and the manufacturer‘s
approved machine data.
2.1 Electrical connection
TU2506 TU2807
230V 750 W ~ 50 Hz 230V 850 W ~ 50 Hz
Connection
2.2 Machine data
Spindle speeds [min -1]
Spindle taper MT4
Spindle hole, rod opening [mm] 26
Bed width [mm] 135 180
Travel of top slide [mm] 70 60
Travel of cross slide [mm] 110 160
Tailstock cone MT2
or
400V 750 W ~ 50 Hz 400V 850 W ~ 50 Hz
TU2506V TU2807V
230V 1.2 kW ~ 50 Hz 230V 1.5 kW ~ 50 Hz
TU2506 TU2807
125 - 2000 150 - 2000
TU2506V TU2807V
30 - 4000 30 - 4000
Tailstock sleeve travel [mm] 65 85
Longitudinal feed [mm/rev] 0.07 0.10 0.14 0.20 0.28 0.4
Pitch - inch [threads/inch]
2.3 Working area
Technical data
Pitch - Metric [mm/rev]
Height [mm] 2000 2000
Length [mm] 2200 2200
Depth [mm] 1900 1900
0.2 0.3 0.4 0.5 0.6 0.62 0.75 0.8 0.88 1.0 1.2
1.25 1.5 1.75 2.0 2.5 3.0 3.5
8 9 9.5 10 11 12 14 16 18 19 20 22 24 28 36
38 40 44 58 56
TU2506 TU2807
TU2506V TU2807V
TU2506 | TU2506V | TU2807 | TU2807V GB
Version 1.0.1 2013-10-31 Page 19Original operating instructions
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MASCHINEN - GERMANY
2.4 Environmental conditions
TU2506 (V) TU2807 (V)
Temperature 5 - 35 °C
Humidity 25 - 80 %
2.5 Operating material
TU2506 (V) TU2807 (V)
Feed gear Mobilgear 627 or a comparable oil
bright steel parts, guideways, oiler e.g. machines oil (Mobil Oil, Fina, ...)
We recommend the use of weapon oil, weapon oil is acid-,
Change gears Chain oil (spray box)
2.6 Emissions
The generation of noise emitted by the lathe is less than 80 dB(A).
stain- and resin-free.
INFORMATION
This numerical value was measured on a new machine under proper operating conditions.
Depending on the age respectively on the wear of the machine it is possible that the noise
behaviour of the machine changes.
Furthermore, the factor of the noise emission is also depending on manufacturing influencing
factors, e.g. speed, material and clamping conditions.
INFORMATION
The mentioned numerical value is the emission level and not necessarily a safe working level.
Though there is a dependency between the degree of the noise emission and the degree of the
noise disturbance it is not possible to use it reliably to determine if further precaution measures
are required or not.
The following factors influence the actual degree of the noise exposure of the operator:
Characteristics of the working area, e.g. size or damping behaviour,
Other noise sources, e.g. the number of machines,
Other processes taking place in the proximity and the period of time during which the oper-
ator is exposed to the noise.
Furthermore, it is possible that the admissible exposure level might be different fr om country to
country due to national regulations.
This information about the noise emission shall allow the operator of the machine to more easily evaluate the endangering and risks.
CAUTION!
Depending on the overall noise exposure and the basic limit values the machine
operators must wear an appropriate hearing protection.
We generally recommend to use a noise protection and a hearing protection.
TU2506 | TU2506V | TU2807 | TU2807VGB
Version 1.0.1 2013-10-31Page 20 Original operating instructions
Technical data
2.7 Dimensions, installation plan TU2506
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MASCHINEN - GERMANY
Img.2-1: Dimensions, installation plan TU2506
Technical data
Version 1.0.1 2013-10-31 Page 21Original operating instructions
TU2506 | TU2506V | TU2807 | TU2807V GB
OPTIMUM
MASCHINEN - GERMANY
2.8 Dimensions, installation plan TU2506V
Img.2-2: Dimensions, installation plan TU2506V
TU2506 | TU2506V | TU2807 | TU2807VGB
Version 1.0.1 2013-10-31Page 22 Original operating instructions
Technical data
2.9 Dimensions, installation plan TU2807
OPTIMUM
MASCHINEN - GERMANY
Img.2-3: Dimensions, installation plan TU2807
Technical data
Version 1.0.1 2013-10-31 Page 23Original operating instructions
TU2506 | TU2506V | TU2807 | TU2807V GB
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MASCHINEN - GERMANY
2.10 Dimensions, installation plan TU2807V
Img.2-4: Dimensions, installation plan TU2807V
TU2506 | TU2506V | TU2807 | TU2807VGB
Version 1.0.1 2013-10-31Page 24 Original operating instructions
Technical data
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2.11 Distance between centres, height of centres TU2506, TU2506V
Img.2-5: Distance between centres, height of centres TU2506, TU2506V
Technical data
Version 1.0.1 2013-10-31 Page 25Original operating instructions
TU2506 | TU2506V | TU2807 | TU2807V GB
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MASCHINEN - GERMANY
2.12 Distance between centres, height of centres TU2807, TU2807V
Img.2-6: Distance between centres, height of centres TU2807, TU2807V
TU2506 | TU2506V | TU2807 | TU2807VGB
Version 1.0.1 2013-10-31Page 26 Original operating instructions
Technical data
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MASCHINEN - GERMANY
3 Assembly
INFORMATION
The lathe is delivered pre-assembled.
3.1 Scope of delivery
When the lathe is delivered, please check immediately that it has not been damaged during
transport. Also check that no fastening screws have come loose.
Compare the scope of delivery with the attached packing list.
3.2 Transport
Centres of gravity
Load suspension point
(Marking of the positions for the
load suspension gear)
Prescribed transportation position
(Marking of the top surface)
Means of transport to be used
Weights
WARNING!
Severe or fatal injuries may occur if parts of the machine tumble or fall down from the
forklift truck or from the transport vehicle. Follow the instructions and information on
the transport case.
WARNING!
The use of unstable lifting and load suspension gear that might break under load can
cause severe injuries or even death.
Check that the lifting and load suspension gear has sufficient load capacity and that it is
in perfect condition. Observe the accident prevention regulations issued by your
Employers Liability Insurance Association or other competent supervisory authority,
responsible for your company.
Fasten the loads properly. Never walk under suspended loads!
Assembly
Version 1.0.1 2013-10-31 Page 27Original operating instructions
TU2506 | TU2506V | TU2807 | TU2807V GB
OPTIMUM
MASCHINEN - GERMANY
3.3 Storage
ATTENTION!
In case of wrong and improper storage electrical and mechanical machine components
might get damaged and destroyed.
Store packed and unpacked parts only under the intended environmental conditions.
Follow the instructions and information on the transport case:
Fragile goods
(Goods require careful handling)
Protect against moisture and humid environment
"Environmental conditions“ on page 20 .
Prescribed position of the packing case
(Marking of the top surface - arrows pointing to the
top)
Maximum stacking height
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 .
TU2506 | TU2506V | TU2807 | TU2807VGB
Version 1.0.1 2013-10-31Page 28 Original operating instructions
Assembly
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3.4 Installation and assembly
3.4.1 Requirements to the installation site
ATTENTION!
Before you install the machine let the ca pacity of the floor loading check by an expert.
The floor or ceiling of the hall must carry the weight of the machine plus any additional
parts and auxiliary equipment, as well as operator and stockpiled materials. If necessary,
the floor must strengthened.
INFORMATION
In order to attain good functionality and a high processing accuracy as well as a long durability
of the machine the installation site should fulfil certain criteria.
Please observe the following points:
The device must only be installed and operated in a dry and well-ventilated place.
Avoid places nearby machines generating chips or dust.
The installation site must be free from vibrations also at a distance of presses, planing
machines, etc.
The substructure must be suitable for turning. Also make sure that the floor has sufficient
load bearing capacity and is level.
The substructure must be prepared in a way that possibly used coolant cannot penetrate
into the floor.
Any parts sticking out such as stops, handles, etc. have to be secured by measures taken
by the customer if necessary in order to avoid endangerment of persons.
Provide sufficient space for the staff preparing and operating the machine and transporting
the material.
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 illuminator.
INFORMATION
The mains plug of the lathe must be freely accessible.
3.4.2 Load suspension point
Fasten the load suspension gear around the lathe bed.
Make sure that you distribute the loads evenly so that the lathe cannot turn over while lift-
ing.
Make sure that no add-on pieces or varnished parts are damaged due to the load suspen-
sion.
3.4.3 Installation
WARNING!
Danger of crushing and overturning. The lathe must be installed by at least 2 people.
Check the horizontal orientation of the base of the lathe with a spirit level.
Check that the foundation has sufficient floor-load capacity and rigidity.
ATTENTION!
An insufficient rigidity of the substructure leads to superposition of vibrations between
the machine and the substructure (natural frequency of the components). Critical
Assembly
TU2506 | TU2506V | TU2807 | TU2807V GB
Version 1.0.1 2013-10-31 Page 29Original operating instructions
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Synchronous belt
Counter pulley
Wrench
Motor pulley
Synchronous belt
Counter pulley
Wrench
Motor pulley
MASCHINEN - GERMANY
speeds and moves in the axis with displeasing vibrations are rapidly achieved in case of
insufficient rigidity of the whole system and will lead to bad turning results.
Position the lathe on the intended foundation.
Secure the lathe using the through holes
with the foundation or substructure.
"Dimensions, installation plan TU2506“ on page 21
"Dimensions, installation plan TU2506V“ on page 22
"Dimensions, installation plan TU2807“ on page 23
"Dimensions, installation plan TU2807V“ on page 24
3.5 Assembly of the synchronous belt and V-belt on the lathe
3.5.1 Assembly of the synchronous belt on the lathe TU 2506, TU 2807, TU2807 V
Install the synchronous belt from the
scope of delivery on the counter pulley
and motor pulley.
Tension the synchronous belt by moving
the counter pulley up.
Tighten with a wrench the hex nut
securely.
Img.3-1: Assembly synchronous belt
The correct tension of the toothed belt has been reached, when you can still bend it approximately 3 mm with your index finger.
3.5.2 Assembly of the synchronous belt on the lathe TU 2506 V
Install the synchronous belt from the
scope of delivery on the counter pulley
and motor pulley.
Tension the synchronous belt by mov-
ing the counter pulley up.
Tighten with a wrench the hex nut
securely.
Img.3-2: Assembly synchronous belt
The correct tension of the toothed belt has been reached, when you can still bend it approx-
imately 3 mm with your index finger.
TU2506 | TU2506V | TU2807 | TU2807VGB
Assembly
Version 1.0.1 2013-10-31Page 30 Original operating instructions
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