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TU2506
Operating manual
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Optimum TU2506, TU2506V, TU2807, TU2807V Operating manual

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Page 1
OPTIMUM
MASCHINEN - GERMANY
Operating manual
Version 1.0.1
Lathe
GB
Page 2
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
TU2506 | TU2506V | TU2807 | TU2807V GB
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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
Version 1.0.1 2013-10-31Page 6 Original operating instructions
Page 7

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
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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
Page 9
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

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Page 10
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
Safety
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OPTIMUM
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.
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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.
Safety
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OPTIMUM
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.
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Page 14
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.
Img.1-1: EMERGENCY-STOP button
Safety
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Page 15
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
Page 16
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.
Safety
Version 1.0.1 2013-10-31Page 16 Original operating instructions
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MASCHINEN - GERMANY
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
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OPTIMUM
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!
Version 1.0.1 2013-10-31Page 18 Original operating instructions
Safety
Page 19
OPTIMUM
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
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OPTIMUM
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.
Version 1.0.1 2013-10-31Page 20 Original operating instructions
Technical data
Page 21
2.7 Dimensions, installation plan TU2506
OPTIMUM
MASCHINEN - GERMANY
Img.2-1: Dimensions, installation plan TU2506
Technical data Version 1.0.1 2013-10-31 Page 21Original operating instructions
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Page 22
OPTIMUM
MASCHINEN - GERMANY
2.8 Dimensions, installation plan TU2506V
Img.2-2: Dimensions, installation plan TU2506V
Version 1.0.1 2013-10-31Page 22 Original operating instructions
Technical data
Page 23
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
Page 24
OPTIMUM
MASCHINEN - GERMANY
2.10 Dimensions, installation plan TU2807V
Img.2-4: Dimensions, installation plan TU2807V
Version 1.0.1 2013-10-31Page 24 Original operating instructions
Technical data
Page 25
OPTIMUM
MASCHINEN - GERMANY
2.11 Distance between centres, height of centres TU2506, TU2506V
Img.2-5: Distance between centres, height of centres TU2506, TU2506V
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Page 26
OPTIMUM
MASCHINEN - GERMANY
2.12 Distance between centres, height of centres TU2807, TU2807V
Img.2-6: Distance between centres, height of centres TU2807, TU2807V
Version 1.0.1 2013-10-31Page 26 Original operating instructions
Technical data
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OPTIMUM
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 usedWeights
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
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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 .
Version 1.0.1 2013-10-31Page 28 Original operating instructions
Assembly
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OPTIMUM
MASCHINEN - GERMANY
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
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OPTIMUM
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.
Assembly
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OPTIMUM
Pulley
V-belt
Hexagon nut
Tension pulley
Motor pulley
MASCHINEN - GERMANY
3.5.3 Assembly of the V-belt on the lathe
Install the V-belt from the scope of deliv-
ery on the pulley and motor pulley.
Note the desired speed.
 "Speed adjustment“ on page 47.Tighten the V-belt using the tension pul-
ley.
Tighten with a wrench the hex nut
securely.
Img.3-3: Assembly V-belt
The correct tension of the V-belt is achieved, when the V-belt with the fingers may be
depressed about 3mm.
ATTENTION! Make sure that the tension pulley has contact always only on the outside
Make sure the tension of the synchronous belt or V-belt is correct. Excessive or insuffi­cient tension may cause damage.
of the V-belt.
3.6 First commissioning
ATTENTION! Before commissioning the machine check all screws, fixtures resp. safety devices and
tighten up the screws if necessary! WARNING!
When first commissioning the lathe by inexperienced staff you endanger people and the machine.
We do not take any liability for damages caused by incorrectly performed commission­ing.
3.6.1 Warming up the machine
ATTENTION! If the lathe and in particular the lathe spindle is immediately operated at maximum load
when it is cold it may result in damages.
If the machine is cold such as e.g. directly after having transported the machine it should be warmed up at a spindle speed of only 500 1/min for the first 30 minutes.
Assembly Version 1.0.1 2013-10-31 Page 31Original operating instructions
3.6.2 Cleaning and lubricating
Remove the anti-corrosive agents on the lathe which had been applied for transportation
and storage. Therefore, we recommend you to use paraffin.
Do not use any solvents, cellulose thinner or any other cleaning agents which might affect
the coating of the lathe when cleaning the lathe. Observe the indications and notes of the
manufacturer for cleaning agents.
Oil all blank machine parts using an acid-free lubricating oil.Grease the lathe according to the lubrication chart.
 "Inspection and maintenance“ on page 77
TU2506 | TU2506V | TU2807 | TU2807V GB
Page 32
OPTIMUM
MASCHINEN - GERMANY
3.6.3 Visual inspection
Check the oil level in the inspection glass of the feed gear. Abb.5-2: “Feed gear oil sight glass“ on page 77
3.6.4 Functional test
Check if all spindles are running smoothly.Check the state of the lathe chuck and the turn ing jaws.
3.6.5 Electrical connection
Connect the electrical supply cable.Check the fusing (fuse) of your electrical supply according to the technical instructions
regarding the total connected power of the lathe.
ATTENTION! For 400V machines
connected. Most motor defects result of wrong connections. For instance if a motor phase is not correctly clamped or connected to the neutral conductor (N). Effects may be as follows:
The motor is getting hot very rapidly.Increased motor noises.The motor has no power.
Make sure that the direction of rotation of the drive motor is correct. If the rotational direction switch is switched to the position to perform clockwise rotations (R) the spindle needs to rotate clockwise. If necessary, exchange two phase connections. If your connector plug is equipped with a phase inverter, this is done by turning it by 180°.
The guarantee will become null and void if the machine is wrongly connected. ATTENTION!
Bei 230V-Maschinen converter must not be operated with a CEE plug. Firmly connect the machine to the terminal box (see EN 50178 / VDE 5.2.11.1) .
TU 2506 VTU 2807 V
INFORMATION
: Imperatively make sure that all 3 phases ( L1, L2, L3) are correctly
: Lathes with a 1-phase AC motor or the control via a frequency
On lathes of the type "VARIO"
protected switch of your electrical supply. In order to avoid malfunction, you either need an Fl protected switch sensitive for pulse current or AC/DC sensitive. FI protector switch
In case of malfunction or release of the FI protected switch, please check the installed type.
the frequency converter (driving regulator) might release the FI
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Assembly
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OPTIMUM
FI protected switch sensitive for pulse current
Type A
F protected switch sensitive to AC/DC
Type B
300 mA
300 mA
MASCHINEN - GERMANY
The following signs indicate if your machine is equipped with on e of the FI protected switches described above.
We recommend you to use an FI protected switch sensitive to AC/DC. FI protected switches sensitive to AC/DC (RCCB, type B are adequate for 1-phase and 3-phase fed frequency con­verters (driving regulator).
An FI protected switch type AC (only for alternating current) is not appropriate for frequency converters. FI protected switches type AC are no longer used.
3.6.6 Functional check
Clamp a workpiece into the lathe chuck of the machine or close the jaws of the lathe chuck
fully before turning on the machine.
WARNING!
Mind the maximum chuck opening.Do not stand in front of the lathe chuck when turning on the machine for the first
time.
3.7 Optional machine accessories
WARNING! Risk by using improper tool holders or operating them at inadmissible speeds.
Only use the tool holders (e.g. drill chuck) which were delivered with the machine or which are offered as optional equipment by OPTIMUM.
Only use tool holders in the intended admissible speed range. Tool holders may only be modified in compliance with the recommendation of OPTI-
MUM or of the manufacturer of the clamping devices.
Designation Item number Designation Item number TU 2506 TU 2807
Face plate 240 mm 344 1352  Face plate 265 mm 344 1452Steady rest 344 1315  Steady rest 344 1415Follow rest 344 1310  Follow rest 344 1410
Chuck flange 160mm 344 1413
TU 2506 / TU2807
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MASCHINEN - GERMANY
Chuck flange 125 mm 344 1311Collet chuck holder ER 25 344 1305Collet chuck holder ER 32 344 1306Set of cutting tools 10mm
11 pcs.
Set of cutting tools 12 mm
9 pcs.
Quick action tool holder
SWH 1-A
3.8 Mounting instruction
3.8.1 Mounting instruction chuck flange
Clean the flange and the machine spindle very thorough and place it on the machine spindle. Measure the inner hole of the jaw chuck and turn this value of the chuck flange to a diameter as
a H7 fit. Turn once easily over the flat surface of the chuck flange. Put the jaw chuck onto the flange.
INFORMATION
The lathe chuck must let itself manually and put on with the aid of a rubber-faced hammer (dis­tribute uniformly light strokes over the front panel).
Tighten fixing screws evenly and alternately. The screws may perform no compulsion onto the drilling wall since the chuck body bends itself
else or the jaws are locked in position. Furthermore, radial runouts can occur. Refinishing on the jaw chuck is inadmissible!
344 1108
344 1211
338 4301
Version 1.0.1 2013-10-31Page 34 Original operating instructions
Assembly
Page 35
3.8.2 Flange for the lathe chuck
Spindle nose
Chuck side
OPTIMUM
MASCHINEN - GERMANY
Img.3-4: Chuck flange
Assembly Version 1.0.1 2013-10-31 Page 35Original operating instructions
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OPTIMUM
Spindle flange
(short-taper seat)
Measuring position
Set screw
Measuring position
MASCHINEN - GERMANY
3.8.3 Mounting instruction of collet chuck holder
Mounting of collet chuck holder 344 1305 on your lathe. Proceed as follows.
Mark out the position of the jaw chuck
at the spindle flange before disman­tling with an e.g. felt-tipped pen. This allows an identical reassembly.
Dismantle the jaw chuck.Clean all faces of the spindle nose and
of the collet chuck holder extremely thoroughly.
Dismantle the thread pins of the jaw
chuck and screw in the thread pins into the collet chuck holder.
Measure the run out of the spindle
flange. Mark out the greatest positive rash of the dial gauge at the spindle flange with an e.g. felt-tipped pen.
Attach the collet chuck hol d er to the
spindle flange, tighten the nuts easily. Pull in the nuts stepwise ones and uni­formly alternating at least three times in succession (you receive the run out possible for best only this way).
Measure the run out of the collet chuck
holder at the conical surface.
Position the collet chuck holder by
turning each 120° at the spindle flange to the highest run out precision is achieved.
Mark out the position of the highest cir-
cularity accuracy of spindle flange with collet chuck holder and assemble after this the collet chuck holder on the highest circularity accuracy position.
Img.3-5: Collet chuck holder 344 1305 without union
nut.
Assembly
Version 1.0.1 2013-10-31Page 36 Original operating instructions
Page 37
3.8.4 Mounting of follow rest TU 2506 (V)
OPTIMUM
MASCHINEN - GERMANY
Img.3-6: Follow rest TU 2506 (V)
3.8.5 Mounting of follow rest TU 2807 (V)
Img.3-7: Follow rest TU2807 (V)
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TU2506 | TU2506V | TU2807 | TU2807V GB
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OPTIMUM
MASCHINEN - GERMANY
3.8.6 Mounting of steady rest TU 2506 (V)
Img.3-8: Steady rest TU2506 (V)
3.8.7 Mounting of steady rest TU 2807 (V)
Img.3-9: Steady rest TU2807 (V)
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Assembly
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4 Operation

1
2
3
4
7
8
9
10
11
14
12
15
5
6
13
16
4.1 Operation TU2506 and TU2807
4.1.1 Control and indicating elements
OPTIMUM
MASCHINEN - GERMANY
Pos. Designation Pos. Designation
1 Change-over switch with OFF position 2 EMERGENCY-STOP button 3 ON/ OFF switch 4 Lathe chuck protection 5 for the protective cover of the headstock 6 Change wheel and infeed table 7 Selector switch for feed direction 8 Selector switch for speed of feed 9 Handwheel lathe saddle 10 Handwheel top slide 11 Feed activation lever 12 Quadruple toolholder 13 Clamping lever tailstock sleeve 14 Tailstock 15 Hand wheel tailstock sleeve 16 Lead screw
Img.4-1: TU2506 and TU2807
Operation Version 1.0.1 2013-10-31 Page 39Original operating instructions
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OPTIMUM
MASCHINEN - GERMANY
4.1.2 Switching elements
Hand actuated auxiliary switch ON
The “hand actuated auxiliary switch ON” switches the rotation of the lathe on.
Hand actuated auxiliary switch OFF
The “hand actuated auxiliary switch OFF”
Change-over switch
The direction of rotation of the lathe can be switched by actuating the change-over switch. It is possible to select a speed for each direction of rotation.
The labeling “R” means right-handed rotation.The labeling “L” means left-handed rotation.
ATTENTION! Wait until the rotation of the spindle has come to complete standstill before changing
the direction of rotation by actuating the change-over switch. If the direction of rotation is changed during operation, the motor and the change-over
switch might get damaged.
switches the rotation of the lathe off.
4.1.3 Switching on the machine
Perform basic setting on the lathe (speed stage, infeed, etc.).Check if the protective cover of the lathe chuck and the protective cover are closed – close
the protective covers if necessary.
Select the direction of rotation.
Actuate the hand-actuated auxiliary switch “On".
4.1.4 Switching off the machine
Actuate the hand-actuated auxiliary switch “Off”.
If the machine stands still for a longer period of time, disconnect the machine from the elec-
trical power supply.
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Operation
Page 41
4.2 Operation TU2506V
1
2
3
4
7
8
9
10
11
14
12
15
5
6
13
16
18
17
19
4.2.1 Control and indicating elements
OPTIMUM
MASCHINEN - GERMANY
Img.4-2: TU2506V
Pos. Designation Pos. Designation
1 Change-over switch with OFF position 2 EMERGENCY-STOP button 3 ON/ OFF switch 4 Lathe chuck protection 5 for the protective cover of the headstock 6 Change wheel and infeed table 7 Selector switch for feed direction 8 Selector switch for speed of feed 9 Handwheel lathe saddle 10 Handwheel top slide 11 Feed activation lever 12 Quadruple toolholder 13 Clamping lever tailstock sleeve 14 Tailstock 15 Hand wheel tailstock sleeve 16 Lead screw 17 Rotation speed indicator 18 Infinitely variable speed adjustme nt 19 Main switch
TU2506 | TU2506V | TU2807 | TU2807V GB
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Page 42
OPTIMUM
MASCHINEN - GERMANY
4.2.2 Switching elements
Hand actuated auxiliary switch ON
The “hand actuated auxiliary switch ON” switches the rotation of the lathe on.
Hand actuated auxiliary switch OFF
The “hand actuated auxiliary switch OFF”
Speed adjustment
It is possible to set the required speed using the speed adjustment.
main switch
Interrupts or connects the power supply.
Change-over switch
The direction of rotation of the lathe can be switched by actuating the change-over switch. It is possible to select a speed for each direction of rotation.
The labeling “R” means right-handed rotation.The labeling “L” means left-handed rotation.
ATTENTION! Wait until the rotation of the spindle has come to complete standstill before changing
the direction of rotation by actuating the change-over switch. If the direction of rotation is changed during operation, the motor and the change-over
switch might get damaged.
switches the rotation of the lathe off.
4.2.3 Switching on the machine
Perform basic setting on the lathe (speed stage, infeed, etc.).Check if the protective cover of the lathe chuck and the protective cover are closed – close
the protective covers if necessary.
Turn the main switch on.
Select the direction of rotation.
Actuate the hand-actuated auxiliary switch “On".
4.2.4 Switching off the machine
Actuate the hand-actuated auxiliary switch “Off”.
If the machine stands still for a longer period of time, switch off the main switch.
Version 1.0.1 2013-10-31Page 42 Original operating instructions
Page 43
4.3 Operation TU2807V
2
2
3
4
7
8
9
10
11
14
12
15
5
6
13
16
18
17
19
4.3.1 Control and indicating elements
OPTIMUM
MASCHINEN - GERMANY
Pos. Designation Pos. Designation
1 Change-over switch with OFF position 2 EMERGENCY-STOP button 3 ON/ OFF switch 4 Lathe chuck protection 5 for the protective cover of the headstock 6 Change wheel and infeed table 7 Selector switch for feed direction 8 Selector switch for speed of feed 9 Handwheel lathe saddle 10 Handwheel top slide 11 Feed activation lever 12 Quadruple toolholder 13 Clamping lever tailstock sleeve 14 Tailstock 15 Hand wheel tailstock sleeve 16 Lead screw 17 Rotation speed indicator 18 Infinitely variable speed adjustme nt 19 Main switch
Img.4-3: TU2807V
TU2506 | TU2506V | TU2807 | TU2807V GB
Version 1.0.1 2013-10-31 Page 43Original operating instructions
Page 44
OPTIMUM
MASCHINEN - GERMANY
4.3.2 Switching elements
Hand actuated auxiliary switch ON
The “hand actuated auxiliary switch ON” switches the rotation of the lathe on.
Hand actuated auxiliary switch OFF
The “hand actuated auxiliary switch OFF”
Speed adjustment
It is possible to set the required speed using the speed adjustment.
main switch
Interrupts or connects the power supply.
Change-over switch
The direction of rotation of the lathe can be switched by actuating the change-over switch. It is possible to select a speed for each direction of rotation.
The labeling “R” means right-handed rotation.The labeling “L” means left-handed rotation.
ATTENTION! Wait until the rotation of the spindle has come to complete standstill before changing
the direction of rotation by actuating the change-over switch. If the direction of rotation is changed during operation, the motor and the change-over
switch might get damaged.
switches the rotation of the lathe off.
4.3.3 Switching on the machine
Perform basic setting on the lathe (speed stage, infeed, etc.).Check if the protective cover of the lathe chuck and the protective cover are closed – close
the protective covers if necessary.
Turn the main switch on.
Select the direction of rotation.
Actuate the hand-actuated auxiliary switch “On".
4.3.4 Switching off the machine
Actuate the hand-actuated auxiliary switch “Off”.
If the machine stands still for a longer period of time, switch off the main switch.
The change gears for the feed are mounted on a quadrant.
Version 1.0.1 2013-10-31Page 44 Original operating instructions
Page 45
OPTIMUM
mm
n/1"
MASCHINEN - GERMANY
4.4 Safety
Use the lathe only under the following conditions:
The lathe is in proper working order.The lathe is used as prescribed.The operating manual is followed.All safety devices are installed and activated.
All failures should be eliminated immediately. Stop the immediately in the event of any abnor­mality in operation and make sure it cannot be started-up accidentally or without authorisation.
Notify the person responsable immediately of any modification.
 "For your own safety during operation“ on page 17
4.5 Operating elements for feed
Infeed speed
Metric thread
Inch thread
Lead screw nut disengaged (feed deactivated)
Lead screw nut engaged (feed activated)
Feed direction
4.6 Tool holder
Clamp the lathe tool into the tool holder. The lathe tool needs to be clamped as short and tight as possible when turning in order to be
able to absorb the cutting force well and reliably during the chip formation. Adjust the height of the tool. Use the tailstock with the center point in order to determine the re-
quired height. If necessary, put the steel washers beneath the tool to achieve the required height.
Version 1.0.1 2013-10-31 Page 45Original operating instructions
TU2506 | TU2506V | TU2807 | TU2807V GB
Page 46
OPTIMUM
Lathe chuck
Lathe chuck
flange
Nuts
Short taper
1
2
3
3
2
1
MASCHINEN - GERMANY
4.7 Lathe chuck
The workpieces must be clamped firmly and securely onto the lathe before they are machined. The clamp should be tight enough to ensure that the workpiece is moved correctly, but not sotight that it is damaged or deformed.
WARNING! Do not clamp any workpieces that exceed the permitted chucking capacity of the lathe
chuck. The clamping force of the chuck is too low if its capacity is being exceeded. The jaws might be getting loose.
ATTENTION! When disassembling the workpiece chuck (lathe chuck), it may fall on the engine bed
and damage the guide rails. Put a wooden plank or another adequate part on the machine bed in order to avoid damage.
Disconnect the machine from the
electrical supply.
Block the revolutions of the spindle
for instance by inserting the square seat of the lathe chuck. Also make sure that the engine bed is not damaged by the arm of the lever.
Img.4-4: Dismantling lathe chuck
Loosen the three nuts on the spindle to disassemble the lathe chuck.Take the lathe chuck to the front.If required, loosen the lathe chuck by knocking slight with a plastic tip or a rubber mallet.
4.7.1 Replacing the clamping jaws on the lathe chuck
CAUTION! The correct position of the clamping jaws is correct if after twisting together of the
chuck jaws are centered at the center.
The clamping jaws and the three-jaw chuck are equipped with numbers. Nevertheless check before the change, if the numbers are readable - if necessary - check the jaws an d their original position. Insert the clamping jaws at the correct position and in the right order into the three-jaw chuck. Do not con­fuse additional markings on the lathe chuck with number sequences.
Img.4-5: Three-jaw chuck / clamping jaws
Version 1.0.1 2013-10-31Page 46 Original operating instructions
Page 47
OPTIMUM
Fastening screws
Tension pulley holder with
tension pulley
Pulleys
of primary transmission
Synchronous belt
Motor pulley
Spindle pulley
Change gears on quadrant
MASCHINEN - GERMANY
4.8 Speed adjustment
Adjust the speed by changing the position of the V-belt on the pulleys. With the "Vario" equipment variant, the speed can be regulated within the corresponding speed
ranges with the aid of a frequency converter. The speed can then be adjusted using the potenti­ometer on the control panel of the lathe.
In order to change the speed or feed, you must first remove the protective cover.
Unscrew the two fastening
screws.
Remove the
protective cover.
Img.4-6: for the protective cover of the headstock
Img.4-7: TU 2506
TU2506 | TU2506V | TU2807 | TU2807V GB
Version 1.0.1 2013-10-31 Page 47Original operating instructions
Page 48
OPTIMUM
Tension pulley holder
Pulleys of primary
transmission
Motor pulley
Nut of tension pulley holder
V-belt
Tension pulley
MASCHINEN - GERMANY
4.8.1 Changing the speed range
Loosen the nut on the tension pulley holder and unwind the V-belt.Lift the V-belt to the relevant position.
Depending on the selected speed, the V-belt will have to be lifted directly onto the motor pul-
ley oronto the pulley of the primary transmission. Two V-belts of different lengths have there­fore been provided for the TU2506 lathe.
Handle the V-belt with care. It must not be damaged or overstretched.
Retighten the tension pulley and fasten the nut again.
The correct tension of the V-belt is achieved, when the V-belt with the fingers may be de-
pressed about 3mm.
ATTENTION! Make sure that the tension pulley has contact always only on the outside
Make sure the tension of the V-belt is correct. Excessive or insufficient tension may cause damage.
4.8.2 Speed table TU 2506
of the V-belt.
Version 1.0.1 2013-10-31Page 48 Original operating instructions
Page 49
4.8.3 Speed table TU 2506V
4.8.4 Speed table TU2807
OPTIMUM
MASCHINEN - GERMANY
4.8.5 Speed table TU 2807V
INFORMATION
For Vario lathes the maximum speeds are technically limited to 400 0 min AC 3. It is impossible to have an effective controlling variable of 225% in the V-belt position AC
3. The full range of controlling variables from 15% to 225% are only available for the V-belt po­sition AC 1.
This setting is intended to prevent the workpiece from getting loose by too high centrifugal force of the clamping jaws on the lathe chuck.
-1
at the V-belt position
TU2506 | TU2506V | TU2807 | TU2807V GB
Version 1.0.1 2013-10-31 Page 49Original operating instructions
Page 50
OPTIMUM
Selector lever
feed direction
Selector lever
Infeed speed,
pitch
Quadrant
Clamping screw
Hexagon key
MASCHINEN - GERMANY
4.9 Feed adjustment
4.9.1 Selector switch
Use the selector rotary switches to select the feed direction and feed speed.
ATTENTION! Wait until the machine has
come to a complete halt before making any change to the selector switches.
Img.4-8: Selector switch
INFORMATION
Use the table on the lathe for selecting the feed speed or the thread pitch. Change the change gears if the required thread pitch cannot be obtained with the installed gear set.
4.9.2 Changing the change gears
The change gears for the feed are mounted on a quadrant.
Disconnect the machine
from the electrical supply.
Loosen the locking screw on
the quadrant.
Swing the quadrant to the
right.
Img.4-9: Locking screw quadrant
Img.4-10: Tilted quadrant
Version 1.0.1 2013-10-31Page 50 Original operating instructions
Page 51
Remove the lock washers of
Lock washer
Screw
Clamping screws
Z1
Z2
Z4
Z3
L
Lead screw 3 mm pitch
1. change gear (drive unit) with 40 teeth, standard
the clamping screws at the
quadrant.
Remove the screw from the
shaft of the feed gear.
Loosen the clamping screws
on the quadrant.
OPTIMUM
MASCHINEN - GERMANY
Img.4-11: Attachment of change gears
Install the gear couples using the feed or change ge ar ta ble a nd scr ew the g ear whee ls onto
the quadrant again.
Swing the quadrant to the left until the gearwheels have engaged again.Re-adjust gear flank clearance by inserting a normal sheet of paper as an adjusting or dis-
tance aid between the gearwheels.
Immobilise the quadrant with the locking screw.Attach the protective cover of the headstock and reconnect the machine to the power sup-
ply.
4.9.3 Arrangement of change gears
Img.4-12: Attachment of change gears
Img.4-13: arrangement of change gears
Version 1.0.1 2013-10-31 Page 51Original operating instructions
TU2506 | TU2506V | TU2807 | TU2807V GB
Page 52
OPTIMUM
i 3xVgx
40x
Z2x Z4
Z2xZ3xL
--------------------------- -
3x0 5 x
40x45x60 45x80x60
-------------------------
075===
i 3xVgx
40x
Z2x Z4
Z2xZ3xL
--------------------------- -
3x0 5 x
40x50x60 50x80x60
-------------------------
075===
i 3xVgx
40x
Z1xZ3
Z2xZ4xL
--------------------------- -
3x0 5 x
40x
25x20
70x75x80
---------------------------
0
08===
i 3xVgx
40x
Z1xZ3
Z2xZ4xL
--------------------------- -
3x0 5 x
40x
30x20
75
x80x85
---------------------------
0
07===
MASCHINEN - GERMANY
4.9.4 Tables for thread-cutting
INFORMATION
The tables for thread-cutting is located on the machine. The tables are built up in a way that you may later on assemble the required combination to cut
a thread without having to look up the details. Ligature as orientation for the caming of one toothed wheel to the following one. The identifier "H" stands for bushing or a small toothed wheel as an auxiliary distance. This smaller toothed wheel as an auxiliary distance must of course not be camed in with any other toothed wheel.
4.9.5 Transmission ratio
The gear transmission ratio is the ratio of the driving toothed wheels to the driven toothed wheels.
Example calculation for a thread of 0.75 mm on lathe TU2506:
Example calculation for a thread of 0.75 mm on lathe TU2807:
Example calculation for a infeed of 0.09 mm on lathe TU2506:
Example calculation for a infeed of 0.07 mm on lathe TU2807:
The figure 3 in the above calculation is the pitch of the lead screw. The figure 40 is the 1st drive unit, with 40 teeths on the main shaft of spindle ( shaft lathe
chuck).
Vg calls the feed gear.
- Feed gear (Vg) position "C" transmission ratio = 0.5
- Feed gear (Vg) position "A" transmission ratio = 1
- Feed gear (Vg) position "B" transmission ratio = 2
Version 1.0.1 2013-10-31Page 52 Original operating instructions
Page 53
OPTIMUM
Selector lever
Lathe saddle
Engaging lever
MASCHINEN - GERMANY
4.9.6 Example - assembly of gear wheels for thread 0.75mm 1.5mm 3mm
Ligatures from one figure to the follow­ing one represent the caming of one toothed wheel to the following one. The identifier "H" stands for bushing or a small toothed wheel as an auxiliary dis­tance, see position 523 of spare parts drawing.
With the shims, see position 518 and 519 of the spare parts drawing, the dis­alignment of the gear wheels is reached.
The designation a b c of the threading table is the meaning of the position of selector switch on feed gear.
Img.4-14: example of gear wheel combination
4.10 Feed engaging lever
ATTENTION! Damage to mechanical parts. The automatic feed is not designed to move onto
mechanical stops or the mechanical end of the headstock.
The automatic longitudinal feed and the feed for thread-cutting are activated and deactivated using the feed engaging lever. The feed is transmitted via the lead screw nut.
Push the feed engaging lever down-
wards. The lead screw nut is
engaged and the automatic longitu-
dinal feed is activated.
Img.4-15: apron TU2807
Pull the feed engaging lever up to stop the automatic longitudinal feed.
INFORMATION
Move the hand wheel of the lathe saddle a little in order to facilitate the locking of the engaging lever.
TU2506 | TU2506V | TU2807 | TU2807V GB
Version 1.0.1 2013-10-31 Page 53Original operating instructions
Page 54
OPTIMUM
Clamping screw
Clamping screw
MASCHINEN - GERMANY
4.11 Fixing the lathe saddle
ATTENTION! The cutting force produced during
facing, recessing or slicing proc­ess may displace the lathe saddle.
Secure the lathe saddle using the
tightening screw.
Img.4-16: Lathe saddle TU2506
Img.4-17: Lathe saddle TU2807
Version 1.0.1 2013-10-31Page 54 Original operating instructions
Page 55
OPTIMUM
Safety screw
MASCHINEN - GERMANY
4.12 Turning tapers
4.12.1 Turning short tapers with the top slide
With the top slide short cone can be rotated. The scaling is performed up to 60° degree of angle. It is also possible to adjust the top slide over the 60°- angular mark.
Loosen the two nuts at the left and right of the top slide.Swivel the top slide.Clamp the top slide again.
4.12.2 Turning tapers with the tailstock
The cross-adjustment of the tailstock is used for turning long, thin bodies.
Loosen the locking nut of the tailstock.Unscrew the locking screw approximately half a turn.
By alternately loosening and tightening the two (front and rear) adjusting screws, the tailstock is moved out of the central position. The desired cross-adjustment can be read off the scale.
First retighten the locking screw and then the two (front and rear) adjusting screws. Re-
tighten the adjusting screws of the tailstoc k.
ATTENTION! Check clamping of the tailstock and the
sleeve, respectively for the turning jobs between the centres!
Tighten the securing screw at the end of the lathe bed in order to prevent the tailstock from unintentional drawing-out of the lathe bed.
Img.4-18: Lathe bed
Version 1.0.1 2013-10-31 Page 55Original operating instructions
TU2506 | TU2506V | TU2807 | TU2807V GB
Page 56
OPTIMUM
2
D
d
Lw
L
2
Kv
L
Dd–
------------ -
=
Vd
100mm
Kv
------------------ -
=
Vo
Vd
2
-------
=
Vo
100mm D d–
2L
------------------------------------------ -
=
Vo
100mm 30mm 24mm–
222mm
------------------------------------------------------------------- -
100mm 6mm
44mm
------------------------------------- -
13=63mm==
MASCHINEN - GERMANY
4.12.3 Turning of cones with high precision
D = large diameter [mm] d = small diameter [mm] L = cone length [mm] Lw = workpiece length [mm]
= cone angle
= setting angle Kv = cone proportion Vr = tailstock offset
Abb.4-19: Designation on the cone
There are different possibilities to machine a cone on a common small lathe:
1. By twisting the compound slide by setting the setting-angle with the angular scale. But there the graduation of the scale is too inaccurate. For chamfers and conic passings the gradua­tion of the angular scale is sufficient.
2. By a simple calculation, a stop measure of 100mm length (of your own production) and a gauge with stand.
Vd = measure change [mm] Vo = twist measure of top slide [mm]
Calculation
of the offset of the top slide relating to the stop measure with a length of 100mm.
Step by step
by one calculation step (summary)
Example: D = 30.0 mm ; d = 24.0 mm ; L = 22.0 mm
The stop measure (100mm) is to be put between a fixed unit stop and the bedslide. Put the gauge with stand on the lathe bed and horizontally align the test prod with the test prod with thetop slide (90° to the top slide). The twisting measure is calculated with the above mentioned formula. The top slide is twisted by this value (then set the gauge to zero). After removing the stop measure, the bedslide will be aligned to the limit stop. The gauge must indicate the calculated value "Vo" Then the workpiece an d the tool are clamped and positioned (the bedslide is fixed).
Version 1.0.1 2013-10-31Page 56 Original operating instructions
Page 57
OPTIMUM
Gauge
Stop measure
Limit stop
Measuring direction
Advance of depth of cut
F
eed
di
r
ec
t
i
o
n
100mm
Gauge
Advance of depth of cut
M
e
a
s
u
r
i
n
g
-
a
n
d
i
n
fe
e
d
d
i
r
e
c
ti
o
F
e
e
d
d
i
r
e
c
ti
o
n
MASCHINEN - GERMANY
The infeed is performed with the handwheel of th e top slide. The depth of cut is ad vanced with the handwheel of the compound slide.
Img.4-20: Cone setting with stop measure
3. By measuring an existing cone with gauge and stand. The stand is put on the top slide. The gauge is aligned horizontally and 90° to the top slide. The
top slide is approximately adjusted to the cone angle and the test prodbrought in contact with the cone surface (fix the bedslide). Now the top slide is twisted in a way that the gauge does not indicate any travel of the pointer over the whole length of the cone (offset over the handwheel of the top slide).
Then you may start reaming the lathe as described under point 2. The workpiece might be a flange for lathe chucks or a face plate.
Img.4-21: Cone setting with stop measure
Version 1.0.1 2013-10-31 Page 57Original operating instructions
TU2506 | TU2506V | TU2807 | TU2807V GB
Page 58
OPTIMUM
Vr
Lw
2Kv
----------------
=
Vr
Dd– 2L
------------ -
Lw=
Vr
max
Lw
50
------- -
=
Vr
150
240
-------------- -
1 875mm==
Vr
max
150
50
-------- -
3mm==
MASCHINEN - GERMANY
4. By offsetting the tailstock as the cone length is larger than the adjustable stroke of the top slide.
The workpiece is clamped be tween two poin ts, therefor e center holes are require d on the face . They are to be drilled before removing the lathe chuck. The slaving of the workpiece is per­formed by a pulling pin and a lathe carrier.
The calculated value "Vr" is the offset meas ure of the tailstock. The offset is monitored with the gauge (also the return travel).
For this type of cone machining the lowest speed is used ! Annotation: In order to check the position of the tailstock axis to the rotation axis, a shaft with two centering-
sis clamped between the points. The stand with the gauge is put on the bedslide. The gauge is aligned 90° to the rotation axis and horizontally brought into contact with the shaft. The gauge will pass along the shaft with the bedslide. There must not be any travel of the pointer along the whole length of the shaft. If a deviation is being shown, the tailstock is to be corrected.
Calculation
or
The tailstock offset must not exceed the value tumbles!
Example: Kv = 1 : 40 ; Lw = 150 mm ; L = 100 mm
Img.4-22: Workpiece between points: Tailstock offset Vr
"Vrmax"
as the workpiece
Version 1.0.1 2013-10-31Page 58 Original operating instructions
Page 59
OPTIMUM
MASCHINEN - GERMANY
4.13 Tailstock sleeve
The tailstock sleeve is used to hold the tools (bits, lathe centres, etc.) The sleeve of the tailstock can a drill chuck used for the recording of drilling and countersinking
tools are set.
Clamp the required tool in the tailstock sleeve.Use the hand wheel to move the sleeve back and forth.Clamp the sleeve with the clamping lever.Use the adjustment and / or setting the [mm] - scale on the sleeve.
4.14 Clamping a workpiece into the three jaw chuck
When the workpiece is being clamped unprofessionally, there is a risk of injury as the work­piece may fly off or the jaws may break. The following examples do not show all possible situa­tions of danger.
wrong right
Clamping length too long, overhang too long.
Clamping diameter too large.
Workpiece is too heavy and clamping grade too short.
Additional support over center or rest.
Use larger lathe.
Support over center, enlarges clamping grade.
Enlarged clamping grades are not available for this three-jaw chuck.
Possibly use larger lathe.
Clamping diameter too short.
TU2506 | TU2506V | TU2807 | TU2807V GB
Version 1.0.1 2013-10-31 Page 59Original operating instructions
Clamp on the largest clamping diameter possi­ble.
Page 60
OPTIMUM
n
Vc 1000
d314
-------------------------
=
MASCHINEN - GERMANY
4.15 Standard values for cutting data when turning
The better the cutting data are selected, the better the turning result. Some standard values for cutting speeds of different materials are listed on the following pages.
 "Cutting speed table“ on page 61
Criteria of the cutting conditions:
Cutting speed: Vc (m/min) Depth of cut: ap (mm) Infeed: f (mm/rev)
Cutting speed:
In order to get the speed for the machine settings of the selected cutting speeds the following formula is to be applied:
Speed: n (1/min) Workpiece diameter: d (mm) For lathes without continuously adjustable drive (V-belt drive, speed gear) the nearest speed is
being selected.
Depth of cut:
In order to achieve a good chipping, the results of the depth of cut divided by the infeed shall re­sult in a figure between 4 and 10.
Example: ap = 1.0mm; f = 0.14mm/U ; and this equals to in a value of 7.1 !
Infeed
The infeed for roughing/turning is to be selected in a way that it does not exceed buff the value of the corner radius.
Example: r = 0.4mm ; equals to fmax. = 0.12mm/rev ! For planing/turning the infeed should be maximum 1/3 of the corner radius. Example: r = 0.4mm ; equals to fmax. = 0.12mm/rev !
Version 1.0.1 2013-10-31Page 60 Original operating instructions
Page 61
4.16 Cutting speed table
Materials Cutting materials
non-alloyed steel; steel casting;
C45; St37
low-alloy steel, steel casting;
42CrMo4; 100Cr6
OPTIMUM
MASCHINEN - GERMANY
Turning Drilling
HSS P10 P20 P40 K10
35 -
- 50 20 -
- 35
100 -
- 150 80 -
- 120
80 -
- 120 60 -
- 100
50 -
- 100 40 -
- 80
-
-
-
-
HC
P40HCK15
70 -
- 180 70 -
- 160
150 -
- 300 120 -
- 250
HC
M15/
K10 90 -
- 180 80 -
- 160
HSS
30 -
- 40 20 -
- 30
high-alloyed steel; steel casting;
X38CrMoV51;
S10-4-3-10
rust-resistant steel
X5CrNi1810;
X10CrNiMoTi12
grey cast iron
GG10 ; GG40
cast iron with nodular graphite
GGG35 ; GGG70
copper, brass
aluminium alloys
Description of the coated hard metals: HC P40 = a PVD - coating TiAlN HC K15 = a CVD - coating TiN-Al
2O3
HC M15/K10 = CVD - coating TiAiN
10 -
- 20
15 -
- 40 10 -
- 25 40 -
- 90 40 -
- 100
70 -
- 110
-
-
-
-
-
-
-
-
-
-
-
-
- TiCN - TiN
50 -
- 90
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
30 -
- 80
-
40
- 190 25 -
- 120 60 -
- 180 80 -
- 200
60 -
- 130
-
-
-
-
-
-
-
-
-
-
80 -
- 220
-
-
90 -
- 200 80 -
- 180 90 -
- 300
100 -
- 400
70 -
- 140
50 -
- 140
70 -
- 150 60 -
- 130 60 -
- 150 80 -
- 200
8 -
- 15
10 -
- 15
20 -
- 30 15 -
- 25 30 -
- 80 40 -
- 80
TU2506 | TU2506V | TU2807 | TU2807V GB
Version 1.0.1 2013-10-31 Page 61Original operating instructions
Page 62
OPTIMUM
Tool
Workpiece
Cutting direction
Wedge
Clearance surface
Chip thickness Chip surface
f
ap
n
Chip surface
Chip angle Positive
positive clearance angle
Clearance surface
Chip surface
Chip angle negative
positive clearance angle
Clearance surface
MASCHINEN - GERMANY
4.17 Terms for the rotating tool
Img.4-23: Geometrically
determined cut­ter for the separa­tion process
Img.4-25: Cut A - A, posi-
tive cutter
Wedge angle
Img.4-24: Cut and chip size
Img.4-26: Cut A - A, nega-
tive cutter
The following factors influence the
chip break when turning Chip angle Setting angle Clearance angle Corner radius r Clearance angle minor cutting edge
Cutting edge geometry
n
Setting angle Cutting speed:
Vc
In most cases the setting angle is depending on the work piece. A setting angle of 45° to 75° is suitable for roughing. setting angle of 90° to 95° (no tendency to chattering) is suitable for plan­ing.
The corner angle serves as passing from the major cutting edge to the minor cutting edge. To­gether with the infeed it determines the surface quality. The corner radius must not be selected too large as this might result in vibrations.
Setting angle minor cutting edge Point angle
Depth of cut: Infeed
ap (mm)
f (mm/U)
Depth of cut: ap
n
Infeed
f
Version 1.0.1 2013-10-31Page 62 Original operating instructions
Page 63
4.17.1 Cutting edge geometry for turning tools
b
t
b


High-speed steel Hard metal
OPTIMUM
MASCHINEN - GERMANY
Clearance
angle
Steel +5° to +7° +5° to +6° +5° to +11° +5° to +7°
Cast non +5° to +7° +5° to +6° +5° to +11° +5° to +7°
non-ferrous metal +5° to +7° +6° to +12° +5° to +11° +5° to +12°
aluminium alloys +5° to +7° +6° to +24° + 5° to +11° +5° to +24°
Chip angle
Clearance
angle
Chip angle
4.17.2 Types of cutting form levels
They are needed to influence the chip drain and the chip shape in order to achieve optimum chipping conditions.
Examples of types of cutting form levels
Img.4-27: Cutting form level Img.4-28: Cutting form level
with fillet
b = 1.0 mm bis 2.2 mm t = 0.4 mm bis 0.5 mm
For infeeds of 0.05 to 0.5mm/U and depths of cut of 0.2mm to 3.0mm. The different apex angles ( of the cutting form level need to conduct the chip.
Img.4-29: Positive apex
angle for planing
b = 2.2mm with fillet
Img.4-30: Neutral apex
angle for planing and roughing
Version 1.0.1 2013-10-31 Page 63Original operating instructions
TU2506 | TU2506V | TU2807 | TU2807V GB
Page 64
OPTIMUM
j
b
f
10°

2°
2°
MASCHINEN - GERMANY
Img.4-31: Negative apex
The ready-ground major cutting edge must be slightly ground with a grindstone for the plan­ing.
For the roughing, a small chamfer must be produced with the grindstone in order to stabilize the cutting edge against striking chips (b
Img.4-32: Stabilize cutting
Polished section for recessing and cutting off
(for chip angle refer to table)
angle for rough­ing
edge
= f x 0.8).
f
Img.4-33: Polished section recessing and cutting off
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OPTIMUM
X
MASCHINEN - GERMANY
Polished section for threading
The point angle or the shape for chasing tools is depending on the type of thread. Also refer to:
 "Thread types“ on page 67 "Pitch angle“ on page 72
The measure X must be larger than the depth of thread. Make save that no chip angle is being ground as in this case there would be a strain of the profile.
Img.4-34: Polished section
for threading
4.18 Tapping of external and internal threads
Threads with smaller diameters and standard thread pitches should be tapped manually on the­lathe with screw-taps or dies by turning the clamping chuck as this is more simple to produce.
CAUTION! Pull off the mains plug of the lathe if you want to tap a thread as described above.
Img.4-35: die Img.4-36: screw tap
Bolts and nuts with large thread diameters, deviating thread pitches or special types of thread,right-handed and left-handed threads may be produced by threading. For this manufac­turing there are as well tool holders and drill rods with exchangeable indexable inserts (one­edged or multiple-edged).
Version 1.0.1 2013-10-31 Page 65Original operating instructions
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Page 66
OPTIMUM
MASCHINEN - GERMANY
Img.4-37: tap external
thread
Img.4-38: tap internal
thread
Version 1.0.1 2013-10-31Page 66 Original operating instructions
Page 67
4.19 Thread types
Nut
Bolt
Nut
Bolt
Nut
Bolt
Nut
Bolt
Nut
Bolt
OPTIMUM
MASCHINEN - GERMANY
Designation Profile Code
letter
ISO-thread M
UN UNC UNF
UNEF
UNS
UNJ UNJ 1/4" - 20UNJ
Whitworth B.S.W.W1/4" in. -20 B.S.W.
Short term (e. g.) Application
M4x12
1/4" - 20UNC - 2A
0,250 - UNC - 2A
and general
Machine tools
mechanical engineering
und
Aircraft
Raumfahrtindustrie
ISO-trapezoid
thread
(one- and multi-
ple- threaded)
Round thread RD RD DIN 405
TR Tr 40 x 7
Tr 40 x 14 P7
for thread
Pipe threads,
Cylindrical threads,
or conical pipe threads
connections which seal
Motion thread,
Leading spindle and transport spindle
Fittings and for
Version 1.0.1 2013-10-31 Page 67Original operating instructions
TU2506 | TU2506V | TU2807 | TU2807V GB
purposes of the fire brigade
Page 68
OPTIMUM
Nut
Bolts
Cone
Nut
Bolt
MASCHINEN - GERMANY
NPT NPT 1“ – 11 ½“ NPT
4.19.1 Metric threads (60° flank angle)
pitch P depth of thread of the bolt h2=0,6134 x P depth of thread of the nut H1 = 0,5413 x P rounding r = 0,1443 x P flank diameter d2 = D2 =d - 0,6493 core removing hole drill = d - P flank angle = 60°
Rohrverschraubungen
Fittings and tube joints
Metric coarse-pitch thread
Sizes in mm: preferably use the threads in column 1
Denomination of
thread
d = D
Column 1 Column 2 Bolts
M 1 0.25 0.838 0.693 0.729 0.153 0.135 0.036 0.75
M 1.1 0.25 0.938 0.793 0.829 0.153 0.135 0.036 0.85
M 1.2 0.25 1.038 0.893 0.929 0.153 0.135 0.036 0.95
M 1.4 0.3 1.205 1.032 1 .0 75 0.184 0.162 0.043 1.1
M 1.6 0.35 1.373 1.171 1.221 0.215 0.189 0.051 1.3
M 1.8 0.35 1.573 1.371 1.421 0.215 0.189 0.051 1.5
M 2 0.4 1.740 1.509 1.567 0.245 0.217 0.058 1.6
M 2.2 0.45 1.908 1.648 1.713 0.276 0.244 0.065 1.8
M 2.5 0.45 2.208 1.948 2.013 0.276 0.244 0.065 2.1
M 3 0.5 2.675 2.387 2.459 0.307 0.271 0.072 2.5
M 3.5 0.6 3.110 2.764 2.850 0.368 0.325 0.087 2.9
pitch P
durchmesser
Flank diameter
d2 = D2
Core diameter
durchmesser
Nut
d3
D1
Depth of thread
Bolts
h3
Nut
H1
Rounding r
Core removing hole driill
M 4 0.7 3.545 3.141 3.242 0.429 0.379 0.101 3.3 M 5 0.8 4.480 4.019 4.134 0.491 0.433 0.115 4.2 M 6 1 5.350 4.773 4.917 0.613 0.541 0.144 5.0
M 8 1.25 7.188 6.466 6.647 0.767 0.677 0.180 6.8 M 10 1.5 9.026 8.160 8.376 0.920 0.812 0.217 8.5 M 12 1.75 10.863 9.853 10.106 1.074 0.947 0.253 10.2
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MASCHINEN - GERMANY
M14 2 12.701 11.546 11.835 1.227 1.083 0.289 12
M 16 2 14.701 13.546 13.835 1.227 1.083 0.289 14
M18 2.5 16.376 14.933 15.294 1.534 1.353 0.361 15.5
M 20 2.5 18.376 16.933 17.294 1.534 1.353 0.361 17.5
M 22 2.5 20.376 18.933 19.294 1.534 1.353 0.361 19.5
M 24 3 22.051 20.319 20.752 1.840 1.624 0.433 21
M 27 3 25.051 23.319 23.752 1.840 1.624 0.433 24 M 30 3.5 27.727 25.706 26.211 2.147 1.894 0.505 26.5 M 36 4 33.402 31.093 31.670 2.454 2.165 0.577 32 M 42 4.5 39.077 36.479 37.129 2.760 2.436 0.650 37.5 M 48 5.5 44.752 41.866 41.866 3.067 2.706 0.722 43 M 56 5.5 52.428 49.252 49.252 3.374 2.977 0.794 50.5 M 64 6 60.103 56.639 56.639 3.681 3.248 0.866 58
Metric fine-pitch thread
Denomi­nation of
thread
d x P
M2 x 0,2 1.870 1.755 1.783 M16 x
Flank
diameter
durch-
messer
d2 = D2
Core diameter Denomi-
nation of
Bolt Nut Bolt Nut
thread
d x P
1,5
Flank
diame-
ter
durch-
messer
d2 = D2
15.026 14.160 14.376
Core diameter
durchmesser
M2.5 x
0.25
M3 x 0,35 2.773 2.571 2.621 M20 x
M4 x 0,5 3.675 3.387 3.459 M24 x
M5 x 0,5 4.675 4.387 4.459 M24 x 2 22.701 21.546 21.835
M6 x 0,75 5.513 5.080 5.188 M30 x
M8 x 0,75 7.513 7.080 7.188 M30 x 2 28.701 27.546 27.835
M8 x 1 7.350 6.773 6.917 M36 x
M10 x
0,75
M10 x 1 9.350 8.773 8.917 M42 x
M12 x 1 11.350 10.773 10.91 7 M42 x 2 40 .7 01 39.546 39.835
M12 x
1.25
M16 x 1 15.350 14.773 14.917 M48 x 2 46.701 45.546 45.835
2.338 2.193 2.229 M20 x 1 19.350 18.773 18.917
19.026 18.160 18.376
1.5
23.026 22.160 22.376
1,5
29.026 28.160 28.376
1,5
35.026 34.160 34.376
1,5
9.513 9.080 9.188 M36 x 2 34.701 33.546 33.835
41.026 40.160 40.376
1,5
11 .188 10.466 10.647 M46 x
1,5
47.026 46.160 46.376
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Version 1.0.1 2013-10-31 Page 69Original operating instructions
Page 70
OPTIMUM
MASCHINEN - GERMANY
4.19.2 British thread (55° flank angle)
BSW (Ww.): British Standard Withworth Coarse Thread Series is the most common coar sepitch thread in Great Britain and corresponds in its usage category to the metric coarse-pitch thread. The designation of a hexagon head screw 1/4" - 20 BSW x 3/4" , is here: . 1/4" is the nominal diameter of the screw and 20 is the number of threads in 1" of length
BSF: British Standard Fine Thread Series. British Standard Fine Thread Series. BSW- and BSF are the thread selection for the common screws. This fine thread is very common in the British machine tool industry, but it is replaced by the American UNF thread.
BSP (R): British Standard Pipe Thread. Cylindric pipe thread; designation in Germany: R 1/4" (nominal width of the tube in inch). Tube threads are larger in their diam eter as "BSW". Desig­nation 1/8" - 28 BSP
BSPT: BSPT: British Standard Pipe - Taper Thread. Conic tube thread, cone 1:16; designation: 1/4" - 19 BSPT
BA: BA: British Association Standard Thread (47 1/2° flank angle). Common with instruments and watches, is being replaced by the metric ISO thread and by the ISO miniature thread. It consists of numeric designations from 25 to 0=6,0mm max diameter.
Table of the British threads
Nominal diameter of
the thread
[Inch] mm (R) D. [mm] Nr. D
1/16 1.588 60 - - 16 134 0.79 3/32 2.382 48 - - 15 121 0.9
1/8 3.175 40 - 28 9.73 14 110 1.0 5/32 3.970 32 - - - 13 102 1.2 3/16 4.763 24 32 - - 12 90.9 1.3 7/32 5.556 24 28 - - 11 87.9 1.5
1/4 6.350 20 26 19 13.16 10 72.6 1.7 9/32 7.142 20 26 - - 9 65.1 1.9 5/16 7.938 18 22 - - 8 59.1 2.2
3/8 9.525 16 20 19 16.66 7 52.9 2.5 7/16 11.113 14 18 - - 6 47.9 2.8
1/2 12.700 12 16 14 20.96 5 43.0 3.2 9/16 14.288 12 16 - - 4 38.5 3.6
5/8 15.875 11 14 14 22.91 3 34.8 4.1
1 1/16 17.463 11 14 - - 2 31.4 4.7
BSW BSF: BSP/BSPT BA-threads
Threads in 1" Threads in 1"
55° Flank angle 47 1/2° Flank angle
[mm]
3/4 19.051 10 12 14 26.44 1 28.2 5.3
13/16 20.638 10 12 - - 0 25.3 6.0
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OPTIMUM
Feed direction
Feed direction
MASCHINEN - GERMANY
7/8 22.226 9 11 14 30.20
15/16 23.813 9 11 - -
1 25.401 8 10 11 33.25 1 1/8 28.576 7 9 - ­1 1/4 31.751 7 9 11 41.91 1 3/8 34.926 6 8 - ­1 1/2 38.101 6 8 11 47.80 1 5/8 41.277 5 8 - ­1 3/4 44.452 5 7 11 53.75 1 7/8 47.627 4 1/2 7 - -
2 50.802 4 1/2 7 1 1 59.62
4.19.3 Indexable inserts
For indexable inserts there are partial profile and full profile indexable inserts. The partial pro­file indexable inserts are designed for a certain pitch range (e.g. 0.5 - 3mm).
The partial profile indexable insert is optimally appropriate for the single-piece production.The full profile indexable insert is only designed for a certain pitch.
Img.4- 39: partial profile
indexable insert
Img.4-40: full profile indexa-
ble insert
Determining the machining method of right-handed and left-handed threads:
Right-handed tool holders or drill rods are used. In order to top right-handed threads the feed direction towards the clamping chuck is selected and the machine spindle turns to the right (the turning direction of the machine spindle is determined when you look into the spindle from the rear side). If a left-handed thread is to be tapped, the feed direction is selected away from the clamping chuck in direction to the tailstock and the machine spindle turns to the right.
Img.4-41: right-handed
thread with the machine spindle turning to the right
Img.4-42: left-handed
thread with the machine spindle turning to the right
TU2506 | TU2506V | TU2807 | TU2807V GB
Version 1.0.1 2013-10-31 Page 71Original operating instructions
Page 72
OPTIMUM
Core diameter
Flank diameter
Thread diameter
tan
P
D
2
---------------- -
=
1 2 3 4 5 6 7
8 9 10 11 12 13 14
MASCHINEN - GERMANY
As for thread cutting there are other conditions as for longitudinal turning, the forward cutter must show a larger clearance as the pitch angle of the thread.
Pitch angle Pitch P
Img.4-43: Pitch angle
4.19.4 Examples for thread cutting
As an example, a metric external thread M30 x 1,0 mm made of brass is being machined.
Selecting the tool holder
For lathe TU1503V and TU1804V , TU2004V, turning tool No.6 and for lathe TU2404 , TU2404V, TU2506 , TU2506V, TU2807 , TU2807V turning tool No.13.
Pointing turning tools are also appropriate Fig 6-14: “tip of cutter DIN 4975“ on page 38 with hard metal plates soldered on of the complete set for the lathe TU1503V and TU1804V , TU2004V, 8mm, 11-pieces, item no. 344 1008 and for lathe TU2404 , TU2404V, TU2506 , TU2506V, TU2807 , TU2807V, 8mm, 11-pieces, item no. 344 1108 .
The above mentioned thread turning tools have a point angle of 60°.
Set of turning tools HM 9mm 344 1011 7-pieces with HM indexable inserts TiN-coated in a wooden case ISO designation tool hold e r Turning tool 1: SWGCR/L0810D05 Turning tool 2: SCLCR/L0810D06 Turning tool 3: SDJCR/L0810D07 Turning tool 4: SDNCN/L0810D07 Turning tool 5: SCLCL0810D06 Turning tool 6: LW0810R/L 04 Turning tool 7: QA0812R/L03
Set of turning tools HM 10mm 344 1111 7-pieces with HM indexable inserts TiN-coated in a wooden case ISO designation tool hold e r Turning tool 8: SWGCR/L1010E05 Turning tool 9: SCLCR1010E06 Turning tool 10: SDJCR/L1010E07 Turning tool 11: SDNCN/L1010E07 Turning tool 12: SCLCR/L1010E06 Turning tool 13: LW1010R/L04 Turning tool 14: QA1012R/L03
Steel sheets are to be laid under the complete tool holder or turning tool to achieve exactly
the turning center.
The lowest spindle speed is set so that the lathe will not coast too long !Mount gear pairing for pitch 1,0mm in the change gear !
Version 1.0.1 2013-10-31Page 72 Original operating instructions
Page 73
Abb.4-44: Thread cutting
Abb.4-45: radial infeed
OPTIMUM
MASCHINEN - GERMANY
The outer diameter had been turned to 30,0mm and the tool holder is clamped in the quadruple holder for thread­ing aligned angular to the rotation axis. The height of centers is checked (as described).
The depth of thread is manufactured in various passes. The infeed is to be reduced after each pass.
The first pass takes place with an infeed of
0.1 to 0.15mm. For the last pass the infeed shall not be
below 0,04mm. For pitches up to 1,5mm the infeed may
be radial. For our example 5 to 7 passes are being
determined.
For larger pitches the alternate flank infeed is selected. The top slide is offset alternately to the left and to the right by 0,05 to 0.10mm each. The last two passes are performed without lateral offset. When the depth of thread is achieved, two passes are performed without infeed.
Abb.4-46: alternate infeed
The cutting point is slit slightly by turning the handwheel of the compound slide the scale is turned to zero. This is the point of departure for the infeed of the depth of thread.
The scale of the compound slide is also set to zero (this is import ant for the later al offset when­turning threads with larger pitches).
The cutting point is set just in front of the starting point of the start of the thread by actuating thehandwheel of the bedslide.
The cutting point is set just in front of the starting point of the start of the thread by actuating thehandwheel of the bedslide. With this connection, the adjusted thread pitch is transfered to the bedslide and to the tool holder.
ATTENTION! This connection must not be disconnected until the thread is finished!
To machine internal threads, about 2 passes shall be selected additionally for the infeed (drill rods are more instable).
TU2506 | TU2506V | TU2807 | TU2807V GB
Version 1.0.1 2013-10-31 Page 73Original operating instructions
Page 74
OPTIMUM
MASCHINEN - GERMANY
Starting the threading:
Radial infeed over the handwheel of the top slide.Turn the change-over, switch to the rightStart the machine and have the first cutting process run.
ATTENTION! Always have the thumb ready on the OFF-switch in order to prevent a collision with the
workpiece or with the clamping chuck !
Immediately turn off the machine at the run out of the thread and cam the cutter out by turn-
ingthe handwheel of the top slide.
Turn the change-over, switch to the left.Turn the machine on and return the bedslide to the starting point and switch the machine
off.
Radial infeed over the handwheel of the top slide.Turn the change-over, switch to the rightSwitch the machine on and have the second cutting process run.Repeat this procedure as often as necessary until the depth of thread is achieved.To check the thread you may use a thread gauge or a workpiece with an internal thread
M30 x 1.0
If the thread is having the exact size, the thread cutting process may be terminated. Now
you may again shift the operating lever of the lead-screw nut in standstill. In this way, the connection between the lead spindle and the bedslide is interrupted.
Now the toothed wheels for the longitudinal feed are to be mounted again!
4.20 Recessing, cutting off and turning off
Friction during the cutting process causes high temperatures at the cutting edge of the tool. The tool should be cooled during the milling process. Cooling the tool with a suitable cooling
lubricant ensures better working results and a longer edge life of the cutting tool.
INFORMATION
Use a water-soluble and non-pollutant emulsion as a cooling agent.This can be acquired from authorised distributors.
Make sure that the cooling agent is properly retrieved. Respect the environment when dispos­ing of any lubricants and coolants. Follow the manufacturer’s disposal instructions.
Version 1.0.1 2013-10-31Page 74 Original operating instructions
Page 75

5 Maintenance

MAINTENANCE
Inspection
Maintenance
Repairs
Measuring
Cleansing Mending
Testing Fine cleaning Replacing
Conserving
Lubricating
Completing
Replacing
Readjusting
Adjusting
In this chapter you will find important information about
InspectionMaintenanceRepairs
of the lathe. The diagram below shows you which tasks belongs to which term.
OPTIMUM
MASCHINEN - GERMANY
Img.5-1: Maintenance – Definition according to DIN 31 051
DANGER ! Properly performed regular maintenance is an essential prerequisite for
operational safety,failure-free operation,long durability of the lathe andthe quality of the products which you manufacture.
Installations and equipment from other manufacturers must also be in good order and condition.
ENVIRONMENTAL PROTECTION During work on the spindle head please make sure that
collector vessels are used with sufficient capacity for the amount of liquid to be col-
lected.
liquids and oils should not be split on the ground.
Clean up any spilt liquid or oils immediately using proper oil-absorption methods and dispose of them in accordance with current legal requirements on the environment.
Collect leakages
Do not re-introduce liquids split outside the system during repair or as a result of leakage from the reserve tank:collect them in a collecting container to be disposed of.
Disposal
Never dump oil or other substances wh ich are ha rmfu l fo r the en vir on m en t in wa te r inle ts , rive rs or channels.
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Page 76
OPTIMUM
MASCHINEN - GERMANY
Used oils must be delivered to a collection centre. Consult your supervisor if you do not know where the collection centre is.
5.1 Safety
WARNING! The consequences of incorrect maintenance and repair work may include:
Very serious injury to personnel working on the lathe,Damage to the lathe.
Only qualified personnel should carry out maintenance and repair work on the lathe.
5.1.1 Preparation
WARNING! Only carry out work on the lathe, if it has been disconnected of the power supply.
 "Disconnecting and securing the lathe“ on page 17
Attach a warning label to the restarting by third parties.
5.1.2 Restarting
Before restarting run a safety check.
 "Safety check“ on page 16
WARNING! Before starting the lathe, you must check that there is no danger for persons and that
theis not damaged.
Version 1.0.1 2013-10-31Page 76 Original operating instructions
Maintenance
Page 77
OPTIMUM
Sight glass
MASCHINEN - GERMANY
5.2 Inspection and maintenance
The type and level of wear depends to a large extent on the individual usage and operating conditions. For this reason, all the intervals are only valid for the authorised conditions.
Interval Where? What? How?
Start of work,
after every
maintenance
or repair work
 "Safety check“ on page 16
Lathe
Start of work, after every
maintenance or repair work
Start of work, after every
maintenance or repair work
Lubricating
Lathe
visual inspection
Feed gear
Lubricate all slideways.Slightly lubricate the change gears and lead screw with
lithium-based grease.
Check the oil level in the sight glass of the feed gear. It
must reach at least the centre of the sight glass.
If necessary, fill up to the reference mark with Mobilgear
627 or equivalent oil.
Abb.5-2: Feed ge ar oil sight glass
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OPTIMUM
Outlet
Filler opening
Oiler
MASCHINEN - GERMANY
Interval Where? What? How?
For oil change use an appropriate collecting tray of suffi-
cient capacity.
Unscrew the screw from the drain hole.Unscrew the screw from the filler hole.Close the drain hole if no more oil drains.Refill with Mobilgear 627 or an equivalent oil up to the ref-
erence mark in the centre of the sight glass using a suita­ble funnel in the filling hole.
First after 200 operating hours,
then every year
Oil change
every month
Oiler
Abb.5-3: gear openings
Lubricate all oilers with machine oil , do not use a grease
gun or similar greasing equipment. Use the oil bottle in the delivery volume.
 "Operating material“ on page 20
Lubricating
Abb.5-4: example, oiler on TU 2807
Maintenance
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OPTIMUM
MASCHINEN - GERMANY
Interval Where? What? How?
Approximately every 100 operation hours a cleaning of the jaw guidance is to be performed, depending on the operating conditions, a complete cleaning is to be performed about every 500 operating hours.
All 100 and 500 operating hours
WARNING! Unadequate lubricants may reduce the clamping force by more than 50%
INFORMATION
The spindle bearings are permanently greased. Greasing during the maintenance intervals is not necessary. Further greasing of the spindle bearings is only necessary in case of de- and remounting of the spindle bearing.
Clean and regrease
Lathe chuck
Leave the jaw chuck on the machine. Clean the jaws (do not use compressed air) and then
unscrew them. Thoroughly clean with kerosene or with benzine.
Relubricate with Molykote TP 42.Make sure that the jaws are in the correct order.
5.3 Repair
For any repair work, request the assistance of an employee of Optimum Maschinen Germany GmbH’s technical service.
If the repairs are carried out by qualified technical staff, they must follow the indications given in these operating instructions.
The company Optimum Maschinen Germany GmbH does not take responsibility nor does it guarantee for damages and failures resulting of non-observance of this operating manual.
For repairs only use
faultless and suitable toolsoriginal parts or parts from series expressly authorized by Optimum Maschinen Germany
GmbH.
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OPTIMUM
MASCHINEN - GERMANY

6 Ersatzteile - Spare parts TU2807 | TU2807V

6.1 Oberschlitten - Top slide
Abb.6-1: Oberschlitten - Top slide TU 2807
TU2506 / TU2807 (Vario)D
Ersatzteile - Spare parts TU2807 | TU2807V
Version 1.0.1 31. Oktober 2013 80 Originalbetriebsanleitung
Page 81
6.2 Planschlitten- Cross slide
OPTIMUM
MASCHINEN - GERMANY
Abb.6-2: Planschlitten - Cross slide
Ersatzteile - Spare parts TU2807 | TU2807V Version 1.0.1 31. Oktober 2013 81Originalbetriebsanleitung
TU2506 / TU2807 (Vario) D
Page 82
OPTIMUM
MASCHINEN - GERMANY
6.3 Bettschlitten - Bed slide
Abb.6-3: Bettschlitten - Bed slide TU 2807
TU2506 / TU2807 (Vario)D
Ersatzteile - Spare parts TU2807 | TU2807V
Version 1.0.1 31. Oktober 2013 82 Originalbetriebsanleitung
Page 83
6.4 Reitstock 2 - Tailstock 2
OPTIMUM
MASCHINEN - GERMANY
Abb.6-4: Reitstock neue Ausführung - Tailstock new type
Ersatzteile - Spare parts TU2807 | TU2807V Version 1.0.1 31. Oktober 2013 83Originalbetriebsanleitung
TU2506 / TU2807 (Vario) D
Page 84
OPTIMUM
MASCHINEN - GERMANY
6.5 Maschinenbett - Machine bed
Abb.6-5: Maschinenbett - Machine bed
TU2506 / TU2807 (Vario)D
Ersatzteile - Spare parts TU2807 | TU2807V
Version 1.0.1 31. Oktober 2013 84 Originalbetriebsanleitung
Page 85
6.6 Vorschubgetriebe 1 von 2 - Feed gear 1 of 2
OPTIMUM
MASCHINEN - GERMANY
Abb.6-6: Vorschubgetriebe 1 von 2 - Feed gear 1 of 2 - TU2807
Ersatzteile - Spare parts TU2807 | TU2807V Version 1.0.1 31. Oktober 2013 85Originalbetriebsanleitung
TU2506 / TU2807 (Vario) D
Page 86
OPTIMUM
MASCHINEN - GERMANY
6.7 Vorschubgetriebe 2 von 2 - Feed gear 2 of 2
Abb.6-7: Vorschubgetriebe 2 von 2 - Feed gear 2 of 2 - TU 2807
TU2506 / TU2807 (Vario)D
Ersatzteile - Spare parts TU2807 | TU2807V
Version 1.0.1 31. Oktober 2013 86 Originalbetriebsanleitung
Page 87
6.8 Spindelstock 1 von 2 - Headstock 1 of 2
OPTIMUM
MASCHINEN - GERMANY
Abb.6-8: Spindelstock 1 von 2 - Headstock 1 of 2
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TU2506 / TU2807 (Vario) D
Page 88
OPTIMUM
MASCHINEN - GERMANY
6.9 Spindelstock 2 von 2 - Headstock 2 of 2
Abb.6-9: Spindelstock 2 von 2 - Headstock 2 of 2
TU2506 / TU2807 (Vario)D
Ersatzteile - Spare parts TU2807 | TU2807V
Version 1.0.1 31. Oktober 2013 88 Originalbetriebsanleitung
Page 89
6.10 Spindelstock - Headstock TU 2807 V
OPTIMUM
MASCHINEN - GERMANY
Abb.6-10: Spindelstock - Headstock TU 2807 V
Ersatzteile - Spare parts TU2807 | TU2807V Version 1.0.1 31. Oktober 2013 89Originalbetriebsanleitung
TU2506 / TU2807 (Vario) D
Page 90
OPTIMUM
MASCHINEN - GERMANY
6.11 Wechselradgetriebe - Change gear
Abb.6-11: Wechselradgetriebe - Change gear
TU2506 / TU2807 (Vario)D
Ersatzteile - Spare parts TU2807 | TU2807V
Version 1.0.1 31. Oktober 2013 90 Originalbetriebsanleitung
Page 91
OPTIMUM
MASCHINEN - GERMANY
6.12 Ersatzteilliste - Spare parts list TU 2807
TU 2807
Pos.
Bezeichnung Designation
1 Klemmhebel Wekrzeughalter Clamping lever tool holder 1 034270011 2 Griff Klemmhebel Handle locking lever 1 034270012 3 Klemmmutter Werkzeughalter Clamping nut tool holder 1 034270013 4 BeilagscheibeKlemmmutter Washer clamping nut 1 034270014 5 Vierfachstahlhalter Quadruple tool holder 1 034270015 6 Gewindestift Grub screw 8 GB 85-88 - M8 x 35 7 Andruckleiste Oberschlitten Pressure border top slide 1 034270017 8 Oberschlitten Top slide 1 034270018
9 Gewindebolzen V i erfachstahlhalter Threaded rod quadruple tool holder 1 034270019 10 Rastbolzen Fixing pin 1 0342700110 11 Feder Spring 1 0342700111 12 Spannstift Spring pin 1 ISO 8752 - 3 x 10 A 13 Innensechskantschraube Socket head screw 4 GB 70-85 - M6 x 16 14 Sechskantmutter Hexagon nut 3 ISO 4032 - M6 15 Spindelmutter Oberschlitten Spindle nut top slide 1 0342700115 15 Messingstift Brass pin 3 03427001 15 16 Schwalbenschwanzfuerung Oberschlitten Dove tail guidance top slide 1 0342700116 17 Klemmring Oberschlitten Clamping ring top slide 1 0342700117 18 Skalenring Winkelskala Oberschlitten Angle scales ring top slide 1 0342700118 19 Innensechskantschraube Socket head screw 2 GB 70-85 - M6 x 20 19 Innensechskantschraube Socket head screw 4 GB 70-85 - M6 x 14 20 Spindel Oberschlitten Spindle top slide 1 0342700120 21 Gl eitbuchse Floating bushing, Sliding bearing 2 0342700121 21 Fuehrungsleiste Planschlitten Guide rail bed slide 1 0342700121 22 Lagerbock Spindel Oberschlitten Saddle spindle top slide 1 0342700122 23 Skalenring Handrad Oberschlitten Scales ring handwheel top slide 1 0342700123 24 Fuehrungsscheibe Skalenring Guide disk scales ring 1 0342700124 25 Hebel Handrad Oberschlitten Lever handwheel top slide 1 0342700125 26 Handgriff Handrad Handle handwheel 1 0342700126 27 Befestigungsschraube Griff Handrad Fixing bolt for handle handwheel 1 0342700127 28 Feder Spring 1 0342700128 28 Feder Wahlschalter Spring rotary switch 1 0342700128 29 Stahlkugel Steel ball 1 5 mm 0342700129 30 Scheibe D isc 1 0342700130 31 Innensechskantschraube Socket head screw 1 GB 70-85 - M6 x 25 32 Bügel Holder 1 0342700132 34 Senkschraube Countersunk screw 2 ISO 7046-1 - M5 x 8 - 4.8 - H 35 Welle Shaft 1 0342700135 36 Späneschutzschild Splinter shield 1 0342700136 37 Sechskanthülse Hexagonal case 1 0342700137
38-1 Innensechskantschraube Socket head screw 1 GB 70-85 - M3 x 8 38-2 Sechskantmutter Hexagon nut 1 ISO 4035 - M3
38 Zahnradkombination Gear wheel combination 1 0342700138 39 Innensechskantschraube Socket head screw 2 GB 70-85 - M3 x 6 40 Öler Oiler 14 6 mm 0342700140 41 Gewindestift Threaded pin 1 ISO 4027 - M6 x 8 42 Innensechskantschraube Socket head screw 1 GB 70-85 - M8 x 12 43 Planschlitten Cross slide 1 0342700143 44 Messingstift Brass pin 3 0342700144 45 Innensechskantschraube Socket head screw 3 GB 70-85 - M6 x 30 46 Sechskantmutter Hexagon nut 4 ISO 4032 - M6 47 Stellschraube Set screw 1 0342700147 48 Andruckleiste Planschlitten Pressure border cross slide 1 0342700148 49 Spindelmutter Planschlitten Spindle nut cross slide 1 0342700149 50 Spindel Planschlitten Spindle cross slide 1 0342700150 52 Scwalbenschwanzfuehrung Planschlitten Dove tail guidance cross slide 1 0342700152 54 Abstreifer Cleaner 2 0342700154 55 Halter Abstreifer Holder for cleaner 2 0342700155 58 Kreuzschlitzschraube Cross slot flat head screw 8 GB 6560-86 - M4x12 59 Paßfeder Key 1 DIN 6885 - A 4 x 4 x 8 61 Innensechskantschraube Socket head screw 1 GB 70-85 - M5 x 10 62 Lagerbock Spindel Planschlitten Saddle spindle cross slide 1 0342700162 64 Innensechskantschraube Socket head screw 2 GB 70-85 - M8 x 20
65 Skalenring Handrad Planschlitten Scales ring cross slide 1 0342700165 66 Handrad Planschlitten Handwheel cross slide 1 0342700166
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TU2506 / TU2807 (Vario) D
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OPTIMUM
MASCHINEN - GERMANY
TU 2807
Pos.
Bezeichnung Designation
68 Buchse Socket 1 0342700168 69 Axial-Rillenkugellager Axially grooved ball bearing 2 51101 04051101 71 Schlosskasten Appron 1 0342700171 72 Handrad Bettschlitten Handwheel bed slide 1 0342700172 73 Griff Handrad Bettschlitten Handle handwheel bed slide 1 0342700173 74 Befestigungsschraube Griff Handrad Fixing bolt handle handwheel 1 0342700174 76 Sicherungsring Circlip 1 DIN 471 - 15 x 1 77 Lagerbock Saddle 1 0342700177 78 Innensechskantschraube Socket head screw 5 GB 70-85 - M5 x 25 79 Gegenlager Back support 1 0342700179 80 verzahnte Welle toothed shaft 1 0342700180 81 Paßfeder Key 1 DIN 6885 - A 3 x 3 x 10 82 Gewindestift Threaded pin 1 ISO 4028 - M6 x 16 83 Scheibe Washer 1 ISO 7090 - 8 - 140 HV 84 selbstsichernde Mutter selflocking nut 1 DIN 6924 - M8 85 Innensechskantschraube Socket head screw 2 GB 70-85 - M12 x 35 86 Skalenring Handrad Bettschlitten Scales ring handwheel bed slide 1 0342700186 87 Fuehrungsscheibe Skalenring Guide disk scales ring 1 0342700187 88 Spannstift Spring pin 1 ISO 8752 - 6 x 45 A 89 Scheibe Einrueckhebel Vorschub Disc for lever longitutional feed 1 0342700189 90 Bewegungsscheibe Schlossmutter Movement disk 1 0342700190 91 Zylinderstift Cylindrical pin 2 ISO 2338 - 6 h8 x 12 92 Schlossmutter Lock nut 1 0342700192 93 Fuehrungsschiene Schlossmutter Guide rail lock nut 2 0342700193 94 Innensechskantschraube Socket head screw 4 GB 70-85 - M6 x 16 95 Stellschraube Set screw 1 0342700195 96 Sechskantmutter Hexagon nut 1 ISO 4032 - M5 97 Stahlkugel Steel ball 1 0342700197 98 Feder Spring 1 0342700198
99 Gewindestift Threaded pin 1 ISO 4026 - M6 x 6 105 Spannstift Spring pin 1 ISO 8752 - 4 x 24 A 109 Nutenschraube Slot screw 2 0342700110 9 110 Sechskantmutter Hexagon nut 2 ISO 4032 - M10 117 Innensechskantschraube Socket head screw 3 GB 70-85 - M5 x 16 118 Innensechskantschraube Socket head screw 5 GB 70-85 - M8 x 30 121 Klemmstück Bettschlittenfuehrung Shim lathe slide guidance 1 03427001121 122 Bettschlittenfuehrung bed slide guidance 1 03427001122 124 Lagerbuchse Bush 1 03427001124 125 Innensechskantschraube Socket head screw 2 GB 70-85 - M8 x 40 126 Halter V Abstreifer Holder fo V cleaner 2 03427001126 127 V Abstreifer V cleaner 2 03427001127 128 Innensechskantschraube Socket head screw 2 GB 70-85 - M3 x 6
129 Rastblech Einrueckhebel Vorschub 134 Griff Einrueckhebel Handle engaging lever 1 03427001134
135 Sprengring Circlip 1 DIN 7993 - A 7 136 Welle Einrueckhebel Shaft engaging lever 1 03427001136 137 Feder Spring 1 03427001137 138 Zylinderschraube mit Schlitz Cheese head screw with slot 1 ISO 1207 - M5 x 8 139 Federblech Spring plate 1 03427001139 142 Zentrierstueck Piece of centering 3 03427001142 143 Gewindestift Threaded pin 3 ISO 4026 - M6 x 10 144 Niet Rivet 2 DIN 7337 - A2.4 x 6 145 Markierung Marking 1 03427001145 146 Scheibe Washer 2 DIN 125 - A 6.4 147 Spannstift Spring pin 1 ISO 8752 - 3 x 16 A 206 Motorkeilriemenscheibe Motor V-belt pulley 1 03427001206 207 Paßfeder Key 1 DIN 6885 - A 6 x 6 x 45 208 Innensechskantschraube Socket head screw 1 GB 70-85 - M6 x 25 228 Sechskantmutter Hexagon nut 4 GB 6170-86 - M8
229-2 Abstandshalter unten Spacer down 2 034270012292 229-1 Abstandshalter oben Spacer above 2 034270012291
230 Scheibe Washer 10 DIN 125 - A 8.4 231 Motor 230V Motor 230V 1 230V 0342806 231 Motor 400V Motor 400V 1 400V 0342801
235 Maschinenbett Lathe bed 1 03427001235 236 Zahnstange Rack 2 03427001236 237 Innensechskantschraube Socket head screw 6 GB 70-85 - M6 x 16
Rest sheet metal engaging lever feed
motion
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OPTIMUM
MASCHINEN - GERMANY
TU 2807
Pos.
Bezeichnung Designation
238 Leitspindel Lead screw 1 TR 20 x 3 03427001238 239 Verbindungsstueck Connecting piece 1 03427001239 240 Innensechskantschraube Socket head screw 3 GB 70-85 - M8 x 25 242 Lagerbock Saddle 1 03427001242 245 Nutmutter Groove nut 2 DIN 1804 - M12 246 Scheibe Washer 1 DIN 125 - A 13 247 Scheibe Washer 10 DIN 125 - A 8.4 249 Innensechskantschraube Socket head screw 3 GB 70-85 - M8 x 25 251 Innensechskantschraube Socket head screw 2 GB 70-85 - M8 x 35 257 Gewindestift Drehfutterflansch Threaded pin jaw chuck flange 3 03427001257 258 Scheibe Washer 6 DIN 125 - A 10.5 259 Innensechskantschraube Socket head screw 3 GB 70-85 - M8 x 20 260 Futterflansch chuck flange 1 03425001260 261 Dreibackenfutter Three jaw chuck 1 125 mm 03425001261 262 Drehfutterschluessel Key for 3 - jaw chuck 1 10 mm 03425001262
263 Schaltergehäuse Switch housing 1 03427001263 264-1 Schalterkombination 230V Switch combination 230V 1 0342151 264-1 Schalterkombination 400V Switch combination 400V 1 0342152 264-1 Schalterkombination 230V Switch combination 230V 1 03421512008 264-1 Schalterkombination 400V Switch combination 400V 1 03421522008
265 Flachkopfschraube mit Kreuzschlitz Cheese head screw 2 ISO 7045 - M4 x 16 - 4.8 - H
266 Innensechskantschraube Socket head screw 4 GB 70-85 - M3 x 8
267 Sichtfenster Drehfutterschutz Sight jaw ckuck protection 1 03427001267
268 Spannstift Spring pin 1 GB 879-86 - 5 x 18
269 Rahmen Drehfutterschutz Frame jaw ckuck protection 1 03427001269
271 Sechskantmutter Hexagon nut 4 ISO 4032 - M3
272 Welle Shaft 1 03427001272
273 Flansch Flange 1 03427001273
274 Positionsschalter Drehfutterschutz Position switch jaw ckuck protection 1 03425001274
275 Scheibe Washer 8 DIN 125 - A 6,4
276 Innensechskantschraube Socket head screw 8 GB 70-85 - M6 x 10
277 Zugentlastung Anschlusskabel Strain relief connection cable 1 PG 19 03425001277
278 Stiftschraube Threaded pin 1 DIN 915 M5 x 12
279 Deckel Schaltergehäuse Cover switch housing 1 03427001279
280 Gewindestift Threaded pin 1 DIN 915 - M5 x 12
282 Sechskantmutter Hexagon nut 2 ISO 4032 - M4
295 Axial Rillenkugellager Axially grooved ball bearing 2 51102 04051102
297 Messing Abscherstift Brass shear pin 1 03427001297
298 Zylinderstift Cylindrical pin 1 ISO 2338 - 5 m6 x 22
301 Sicherungsring Circlip 2 DIN 471 - 18 x 1,2
302 Zahnrad Gear wheel 1 24 Z m1.25 15 mm 03427001302
304 Welle Shaft 1 03427001304
305 Zahnrad Gear wheel 1 03427001305 305-1 Zahnrad Gear wheel 1 034270013051 305-2 Sicherungsring Retaining ring 1 DIN 471/16-1
310 Gewindestift Threaded pin 1 ISO 4027 - M6 x 10
311 Gehause Vorschubgetriebe Housing feed gear 1 03427001311
312 Oelverschlussschraube Oil plug 2 03427001312
314 Buchse Socket 1 03427001312
315 Gewindestift Threaded pin 1 ISO 4028 - M6 x 16
316 Flansch Flange 1 03427001316
319 Eingangswelle Entrance shaft 1 03427001319
320 Gleitlager Sliding bearing 1 03427001320
321 Zahnrad Gear wheel 1 32 Z m 1.25 6 mm 03427001321
324 verzahnte Welle toothed shaft 1 16 Z m1.25 03427001324
325 Paßfeder Key 2 03427001325
326 Sicherungsring Circlip 2 DIN 471 - 15 x 1
327 Zahnrad Gear wheel 1 24 Z m1.25 6 mm 03427001327
328 Rillenkugellager Grooved ball bearing 2 6202 0406202.2R
329 Flansch Flange 1 03427001329
330 Innensechskantschraube Socket head screw 6 GB 70-85 - M5 x 10
331 Deckel Vorschubgetriebe Cover feed gear 1 03427001331
332 Innensechskantschraube Socket head screw 5 GB 70-85 - M6 x 16
335 Wahlschalter Rotary switch 2 03427001335
343 Zylinderstift Cylindrical pin 1 ISO 2338 - 3 h8 x 14
343 Zylinderstift Cylindrical pin 1 ISO 2338 - 3 h8 x 14
344 Mitnehmerhuelse Case 1 03427001344
345 Scheibe Disc 1 03427001345
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OPTIMUM
MASCHINEN - GERMANY
TU 2807
Pos.
Bezeichnung Designation
346 Rueckwanddeckel Backwall cover 1 03427001346 347 Senkschraube mit Kreuzschlitz H Countersunk screw 10 GB 819 -85 - M5x8 348 O-Ring O-ring 2 DIN 3771 - 15 x 1.8 349 Buchse rechts Socket right 1 03427001349 350 Gleitlager Zwischenwelle Sliding bearing intermediate shaft 1 03427001350 354 Innensechskantschraube Socket head screw 4 GB 70-85 - M6 x 50 360 Oelschauglas Oil sight glass 1 25 mm 03427001360 361 O-Ring O-ring 1 DIN 3771 20x2,65 402 Scheibe Washer 6 DIN 125 - A 10.5 403 Stiftschraube Threaded pin 2 GB 897-88 - A M10x120 404 Sechskantmutter Hexagon nut 10 GB 6170-86 - M10 405 Mutter Schutzabdeckung 1 03425001405 406 Spindel Spindle 1 03427001406 407 Paßfeder Key 1 DIN 6885 - A 8 x 7 x 40 408 Lagerabdeckung vorne Bearing cover in front 1 03427001408 414 Kegelrollenlager Taper roller bearing 2 32009 04032009 415 Lagerabdeckung hinten Bearing cover in in the back 1 03427001415 416 Distanzhülse Spacer 1 03427001416 417 Zahnrad Toothed wheel 1 03427001417 419 Keilriemen lang V - belt long 1 10 x 850 0392850 420 Spindelkeilriemenscheibe Spindle V-belt pulley 1 03427001420 421 Innensechskantschraube Socket head screw 4 GB 70-85 - M5 x 10 422 Lagerring Bearing ring 2 03427001422 423 Wellenmutter Shaft nut 1 03427001423 424 Welle Shaft 1 03427001424 425 Zahnriemen Toothed belt 1 240L075 0392800 427 Zahnriemenscheibe Toothed belt disk 1 03427001427
428 Sicherungsring Circlip 2 DIN 471 - 12 x 1 430-1 Bundscheibe hinten Flanged washer in front 1 034270014301 430-2 Bundscheibe vorne Flanged washer in the back 1 034270014302
430 Motorzahnriemenscheibe Motor V-belt pulley 1 03427001430
433 Scheibe Washer 1 DIN 125 - A 8,4
434 Innensechskantschraube Socket head screw 1 GB 70-85 - M8 x 35
436 Exzenterscheibe Spannrolle Eccentric disk idler 1 03427001436
437 Welle Spannrolle Shaft for idler 1 03427001437
438 Rillenkugellager Grooved ball bearing 2 6001RZ 0406001.2R
439 Spannrolle Idler 1 03427001439
440 Sicherungsring Circlip 3 DIN 472 - 28 x 1.2
441 Schutzabdeckung Spindelstock Protection cover headstock 1 03427001441 441-3 Falldeckel Drop cover 1 034270014413 441-2 Zylinderschraube mit Schlitz Cheese head screw with slot 1 ISO 7045 - M5 x 10 441-1 Scheibe Washer 1 DIN 125 - A 5.3
443 Scheibe Washer 1 03427001443
453 Sechskantmutter Hexagon nut 1 ISO 4032 - M10
454 Rillenkugellager Grooved ball bearing 2 6001_Z 0406001.2R
455 Scheibe Washer 1 DIN 125 - A 10.5
470 Grundplatte Baseplate 1 03427001470
472 Scheibe Washer 3 DIN 125 - A 8.4 473 Innensechskantschraube Socket head screw 2 GB 70-85 - M8 x 20 502 Innensechskantschraube Socket head screw 1 DIN 912 M8 x 35 503 Wechselradschiene Change gear train 1 03425001503 504 Lagerbock Wechselradschiene Saddle change gear train 1 03427001504 505 Innensechskantschraube Socket head screw 3 DIN 912 M5 x 10 506 Wechselrad, t=9 mm, Di=14 mm Change gear 1 85 Zähne, Modul 1,5 03425001506 507 Wechselrad, t=9 mm, Di=14 mm Change gear 1 80 Zähne, Modul 1,5 03425001507
508 Wechselrad, t=9 mm, Di=14 mm Change gear 1 75 Zähne, Modul 1,5 03425001508
509 Wechselrad, t=9 mm, Di=14 mm Change gear 1 65 Zähne, Modul 1,5 03425001509
510 Wechselrad, t=9 mm, Di=14 mm Change gear 2 60 Zähne, Modul 1,5 03425001510
511 Wechselrad, t=9 mm, Di=14 mm Change gear 1 50 Zähne, Modul 1,5 03425001511
512 Wechselrad, t=9 mm, Di=14 mm Change gear 1 70 Zähne, Modul 1,5 03425001512
514 Wechselrad, t=9 mm, Di=14 mm Change gear 1 45 Zähne, Modul 1,5 03425001514
515 Wechselrad, t=9 mm, Di=14 mm Change gear 1 30 Zähne, Modul 1,5 03425001515
516 Wechselrad, t=9 mm, Di=14 mm Change gear 1 20 Zähne, Modul 1,5 03425001516
517 Nutenstein Wechselradschiene Groove stone change gear 2 M5 03425001517
518 Distanzscheibe Shim 1 1,5 mm 03425001518
519 Distanzscheibe Shim 1 3 mm 03425001519
520 Verbindungshülse Wechselräder Connecting case of change gears 2 03425001520
521 Klemschraube Wechselrad Clamping screw change gear 2 03425001521
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OPTIMUM
MASCHINEN - GERMANY
TU 2807
Pos.
Bezeichnung Designation
522 Befestigungsring Attachment ring 1 03425001522 523 Hülse Wechselrad Case change gear 1 03425001523 524 Scheibe Washer 1 03425001524 525 Innensechskantschraube Socket head screw 1 DIN 912 M6 x 10 601 Spritzwand D280x700G/TU2807 Splash wall D280x700G/TU2807 1 03427001601
601 Spritzwand D280x700 DC Vario/TU2807V 602 Kreuzschlitzschraube Cross slot flat head screw 6 GB 6560-86 - M5x10
603 Abdeckblech Cover plate 1 03427001603 605 Innensechskantschraube Socket head screw 10 GB 70-85 - M3 x 8 605 Innensechskantschraube Socket head screw 10 GB 70-85 - M3 x 5 607 Gewindeschneidtabelle Thread cutting table 1 03427001607 611 Spänewanne D280x700G/TU2807 Chip pan D280x700 G/TU2807 1 03427001611
611 612 Gummiablage Rubber 1 03427001612
615 Schaltkasten für Vario Switch box for Vario type 1 03425001615 901 Unterbau Reitstock Base plate tailstock 1 03427001901 902 Innensechskantschraube Socket head screw 2 GB 70-85 - M8 x 40 903 Reitstock Oberteil Tailstock upper section 1 03427001903 904 Verstelleinrichtung Adjustment device 1 03427001904 905 Gewindestift Threaded pin 1 ISO 4028 - M6 x 16 906 Klemmteil Pinole Clamping piece spindle sleeve 2 03427001906 907 Klemmteil Pinole Clamping piece spindle sleeve 1 03427001907 908 Pinole Spindle sleeve 1 03427001908 909 Spindel Spindle 1 03427001909 910 Zentrierstück Pinole Piece of centering of spindle sleeve 1 03427001910 911 Innensechskantschraube Socket head screw 2 GB 70-85 - M5 x 16 912 Skalenring Scales ring 1 03427001912 913 Zentrierring Centering ring 1 03427001913 914 Kugel Steel ball 1 D = 5 mm 03427001914 915 Spiralfeder Spiral spring 1 03427001915 916 Paßfeder Key 1 DIN 6885 - A 3 x 3 x 10 917 Innensechskantschraube Socket head screw 3 ISO 4026 - M6 x 10 918 Messingklemmstück Brass clamping piece 3 03427001918 919 Handrad Handwheel 1 03427001919 920 Sechskantmutter Hexagon nut 1 DIN EN 24 032 M8 921 Unterlegscheibe Disc 1 03427001921 922 Handgriff Handrad Handle handwheel 1 03427001922 923 Befestigungsschraube Griff Handrad Fixing bolt for handle handwheel 1 03427001923 925 Klemmmutter Clamping nut 1 03427001925 926 Unterlegscheibe Disc 1 D = 8 03427001926 927 Griff Spannhebel Handle clamping lever 1 03427001927 928 Spannhebel Clamping lever 1 03427001928 929 Scheibe Innensechskantschraube 1 03427001929 930 Spannstift Spring pin 1 ISO 8752 - 4 x 28 A 931 Fuehrungsbuchse Guide bush 1 03427001931 932 Spannstift Spring pin 1 ISO 8752 - 4 x 24 A 933 Gewindestange Threaded rod 1 03427001933 934 Spannschraube Tightening screw 1 03427001934 935 Feder Spring 1 03427001935 936 Klemmplatte Clamping plate 1 03427001936 937 Sechskantmutter Hexagon nut 1 ISO 4035 - M12 938 Scheibe Washer 2 DIN 125-1 A 13 939 Zentrierstueck Pinole Piece of centering of spindle sleeve 1 03427001939 940 Skala Skale 1 03427001940 941 Exzenter Eccentric cam 1 03427001941 942 Gewindestift Threaded pin 2 ISO 4028 - M5 x 12 945 Spannhebel Clamping lever 1 03427001945
946 Markierung Marking 1 03427001946 948 Grundplatte Base plate 1 03427001948 949 Reitstock Oberteil Tailstock upper section 1 03427001949 950 Niet Rivet 4 DIN 7337 - A2.4 x 6 951 Not-Aus-Schalter Emergency stop button 1 03427001951 952 Trafo Transformer 1 03427001952 953 Schalter R-und L-Lauf Change over switch 1 03427001953 954 Positionsschalter Spinde lstockabdeckung Position switch headstock protection 1 03427001954 955 Kondensator (230V) Capacitor (230V) 1 150µF 03427001955
Spänewanne D280x700 DC Vario/
TU2807V
Splash wall D280x700 DC Vario/
TU2807V
Chip pan D280x700 DC Vario/TU2807V 1 03427006611
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OPTIMUM
MASCHINEN - GERMANY
TU 2807
Pos.
Bezeichnung Designation
956 Kondensator (230V) Capacitor (230V) 1 30µF 03427001956
C1 Frequenzumrichter Frequency converter 1 Lenze 8200 vector 0313125 C2 Funktionsmodul Functionmodule 1 0313105
P3 Potentiometer Potentiometer 1 1KÙ 0313199
6.12.1 Ersatzteilliste TU 2807 V - Spare parts list TU 2807 V
TU 2807 V
Bezeichnung Designation
Pos.
1 Riemenscheibe Belt pulley 1 0342700601 2 Bundscheibe Flanged washer 1 0342700602 3 Antriebsrad Drive gear 1 0342700603 4 Bundscheibe Flanged washer 1 0342700604 5 Distanzscheibe Spacer 1 0342700605 6 Motorhalterung Motor bracket 1 0342700606 7 Passfeder Fitting key 1 DIN 6885/A6x6x45 0342700607 8 Innensechskantschraube Socket head screw 4 GB 70-85/M8x25 0342700608
9 Motor Motor 1 03338430353 10 Brushlesscontroller Brushlesscontroller 1 03021303201 11 Hauptschalter Main switch 1 03338120S1.1 12 Sechskantmutter Hexagon nut 4 GB 6170/M8 0342700612 13 Scheibe Washer 4 8 0342700613 14 Bolzen Bolt 4 0342700614 15 Endschalter Riemenabdeckung Cover limit switch 1 0460015 16 Riemenscheibe Belt pulley 1 0342700616 17 Riemenscheibe Belt pulley 1 0342700617 18 Zahnriemen Timing belt 1 240L075 0342700618 19 Keilriemen V-belt 1 7M 875 0395250 20 Buchse Bushing 1 0342700620 21 Innensechskanzschraube Socket head screw 2 0342700621 22 Halterung Bracket 1 0342700622 23 Drehzahlsensor Rotation speed sensor 1 03338120279 24 Endschalter Drehfutterschutz Lathe chuck cover switch 1 0460015 25 Abdeckung Cover 1 0342700625 26 Drehfutterschutz Lathe chuck cover 1 0342700626 27 Platte Plate 1 0342700627 28 Potentiometer Potentiometer 1 03338120R1.5 29 Drehzahlanzeige Rotation speed display 1 03338120P1 30 Rechts-Links-Schalter Change-over switch 1 0460009 31 Taste St art Button On 1 03338453188 32 Not-Aus-Taster Emergency stop button 1 03338120S1.2 33 Taste Aus Button off 1 03338453187 35 Abdeckung Cover 1 0342700635
Menge Größe Artikelnummer
Qty. Size Item no.
Menge Größe Artikelnummer
Qty. Size Item no.
TU2506 / TU2807 (Vario)D
Ersatzteile - Spare parts TU2807 | TU2807V
Version 1.0.1 31. Oktober 2013 96 Originalbetriebsanleitung
Page 97
6.13 Maschinenschilder - Machine labels TU 2807
OPTIMUM
MASCHINEN - GERMANY
Abb.6-12: Maschinenschilder - Machine labels
6.13.1 Maschinenschilder - Machine labels TU 2807
Bezeichnung Designation
Pos.
1 Frontschild Front label 1 03427001L01 2 Sicherheitsschild Safety label 1 03425001L02 3 Sicherheitsschild Safety label 1 03425001L05 4 Hinweisschild Instruction label 1 03425001L04
5 Motorschild Motor lable 1
6 Maschinenschild Machine label 1 7 Frontschild Front label 1 03427001L07
8 Gewindeschneidtabelle Tapping table 1 03427001L08
Ersatzteile - Spare parts TU2807 | TU2807V Version 1.0.1 31. Oktober 2013 97Originalbetriebsanleitung
Menge Grösse Artikelnummer
Quantity Size Article no.
TU2807 (230V) 03427001L05 TU2807 (400V) 03427003L05 TU2807 (230V) 03427001L06 TU2807 (400V) 03427003L06
TU2506 / TU2807 (Vario) D
Page 98
OPTIMUM
MASCHINEN - GERMANY
6.14 Maschinenschilder - Machine labels TU 2807 V
Abb.6-13: Maschinenschilder - Machine labels
6.14.1 Maschinenschilder - Machine labels TU 2807 V
Bezeichnung Designation
Pos.
1 Frontschild Front label 1 03427006L01 2 Sicherheitsschild Safety label 1 03425001L02 3 Maschinenschild Machine label 1 03427006L03 4 Frontschild Front label 1 03427006L03 5 Sicherheitsschild Safety label 1 03425001L05 6 Gewindeschneidtabelle Tapping table 1 03427006L06 7 Hinweisschild Instruction label 1 03425001L04
TU2506 / TU2807 (Vario)D
Menge Grösse Artikelnummer
Quantity Size Article no.
Ersatzteile - Spare parts TU2807 | TU2807V
Version 1.0.1 31. Oktober 2013 98 Originalbetriebsanleitung
Page 99

7 Ersatzteile - Spare parts TU2506 | TU2506V

7.1 Oberschlitten - Top slide
OPTIMUM
MASCHINEN - GERMANY
Abb.7-1: Oberschlitten - Top slide TU 2506
Ersatzteile - Spare parts TU2506 | TU2506V Version 1.0.1 31. Oktober 2013 99Originalbetriebsanleitung
TU2506 | TU2506V D
Page 100
OPTIMUM
MASCHINEN - GERMANY
7.2 Planschlitten- Cross slide
Abb.7-2: Planschlitten - Cross slide TU 2506
TU2506 | TU2506VD
Ersatzteile - Spare parts TU2506 | TU2506V
Version 1.0.1 31. Oktober 2013 100 Originalbetriebsanleitung
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