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Southbend SB User Manual

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Page 1
13" HEAVY 13® GEARHEAD LATHE
MODEL SB1049 13" X 30" MODEL SB1050 13" X 40"
OWNER'S MANUAL
© January, 2012 by South Bend Lathe Co. For Machines Mfg. Since 5/11
Page 2
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This manual helps the reader understand the machine, how to prepare it for operation, how to control it durin
nderstanding of how to operate this type of machine, but that the reader is not familiar with the
ontrols and adjustments of this specific model. As with all machinery of this nature, learning the
uances of operation is a process that happens through training and experience. If you are not an
xperienced operator of this type of machinery, read through this entire manual, then learn more
from an experienced operator, schooling, or research before attempting operations. Following this
dvice will help you avoid serious personal injury and get the best results from your work.
eration, and how to keep it in good working condition. We assume the reader has a basic
Manual Feedback
We've made every effort to be accurate when documenting this machine. However, errors sometimes
en or the machine design changes after the documentation process—so
xactly match your machine. If a difference between the manual and machine leaves you in doubt,
n
We highly value customer feedback on our manuals. If you have a moment, please share your
xperience using this manual. What did you like about it? Is there anything you would change to
ake it better? Did it meet your expectations for clarity, professionalism, and ease-of-use
r
mer service for
larifi
e manual may not
South Bend Lathe, Inc
echnical Documentation Manager
Box 202 e mail: manuals@southbendlathe.com
am, WA 9822
ates
For your convenience, any updates to this manual will be available to download free of charge
hrough our website at
www
ustomer
e stand behind our machines. If you have any service questions, parts requests or general questions
out your purchase, feel free to contact us.
h Bend Lathe P Bellingham, WA 9822 Phone: (360) 734-154 Fax: (360) 676-1075 (International Fax: (360) 734-1639 (USA Onl
x 202
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Page 3
Table of Contents
INTRODUCTION .................................................... 3
About This Machine .............................................3
Foreword ............................................................. 3
Capabilities ......................................................... 3
Features .............................................................. 3
General Identification ..........................................4
Controls & Components.......................................5
Master Power Switch ........................................... 5
Headstock ...........................................................5
Control Panel ......................................................6
Carriage .............................................................. 6
Tailstock .............................................................7
End Gears ...........................................................7
Safety Foot Brake ................................................ 7
Product Specifications .........................................8
SAFETY ................................................................12
Understanding Risks of Machinery ..................12
Basic Machine Safety ........................................12
Additional Metal Lathe Safety .......................... 14
Additional Chuck Safety....................................15
PREPARATION .................................................... 16
Preparation Overview ........................................ 16
Things You'll Need ............................................. 16
Power Supply Requirements ............................. 17
Availability ........................................................ 17
Full-Load Current Rating ..................................17
Circuit Requirements ......................................... 17
Grounding Requirements ................................... 18
Extension Cords ................................................18
Unpacking ..........................................................19
Inventory ............................................................ 19
Cleaning & Protecting .......................................20
Location .............................................................. 21
Physical Environment ........................................ 21
Electrical Installation ........................................ 21
Lighting ............................................................21
Weight Load ...................................................... 21
Space Allocation ................................................21
Lifting & Moving ................................................ 22
Leveling & Mounting ......................................... 23
Leveling ............................................................23
Bolting to Concrete Floors ..................................24
Assembly ............................................................24
Lubricating Lathe ..............................................24
Adding Coolant ..................................................25
Power Connection .............................................. 25
Test Run ............................................................. 26
Spindle Break-In ................................................ 30
Recommended Adjustments .............................. 30
OPERATION ........................................................31
Operation Overview ........................................... 31
Chuck & Faceplate Mounting ........................... 32
Installation & Removal Devices ........................32
Chuck Installation ............................................. 33
Registration Marks ............................................ 34
Chuck Removal .................................................. 34
Scroll Chuck Clamping ...................................... 35
4-Jaw Chuck ....................................................... 35
Mounting Workpiece .......................................... 35
Faceplate ............................................................36
Tailstock ............................................................. 37
Positioning Tailstock .........................................37
Using Quill ........................................................ 37
Installing Tooling ..............................................38
Removing Tooling .............................................. 39
Offsetting Tailstock ...........................................39
Aligning Tailstock to Spindle Centerline ............40
Centers ...............................................................41
Dead Centers .....................................................41
Live Centers ...................................................... 42
Mounting Dead Center in Spindle ...................... 42
Removing Center from Spindle ........................... 42
Mounting Center in Tailstock ............................. 42
Removing Center from Tailstock ........................43
Mounting Workpiece Between Centers ............... 43
Steady Rest ........................................................44
Follow Rest ......................................................... 45
Carriage & Slide Locks ...................................... 45
Compound Rest ..................................................46
Four-Way Tool Post ........................................... 46
Installing Tool ................................................... 46
Aligning Cutting Tool with Spindle Centerline ...47
Adjustable Feed Stop ......................................... 48
Micrometer Stop.................................................48
Manual Feed ......................................................49
Carriage Handwheel .......................................... 49
Cross Slide Handwheel ...................................... 49
Compound Rest Handwheel ............................... 49
Spindle Speed ..................................................... 49
Determining Spindle Speed ................................ 49
Page 4
Setting Spindle Speed ........................................ 50
Configuration Examples ..................................... 50
Power Feed ......................................................... 51
Power Feed Controls .......................................... 52
Setting Power Feed Rate ....................................53
End Gears ........................................................... 54
Standard End Gear Configuration ...................... 54
Alternate Configuration ..................................... 55
Threading ........................................................... 56
Headstock Threading Controls ........................... 56
Apron Threading Controls..................................57
Thread Dial ....................................................... 57
Thread Dial Chart .............................................58
Chip Drawer ....................................................... 59
Coolant System .................................................. 60
ACCESSORIES ...................................................61
MAINTENANCE ................................................... 64
Maintenance Schedule ....................................... 64
Cleaning & Protecting ....................................... 64
Maintenance Chart ............................................ 65
Lubrication ......................................................... 66
Headstock .........................................................66
Quick-Change Gearbox ...................................... 67
Apron ................................................................ 67
One-Shot Oiler ..................................................68
Longitudinal Leadscrew .....................................68
Ball Oilers & Oil Cup .........................................69
End Gears .........................................................70
Coolant System Service ..................................... 71
Hazards.............................................................71
Adding Fluid .....................................................72
Changing Coolant .............................................. 72
Machine Storage ................................................ 73
SERVICE .............................................................. 74
Backlash Adjustment ........................................74
Compound Rest .................................................74
Cross Slide ........................................................74
Leadscrew End Play Adjustment ......................75
Gib Adjustment .................................................. 75
Half Nut Adjustment ......................................... 77
V-Belts ................................................................ 77
Brake & Switch .................................................. 78
Leadscrew Shear Pin Replacement ..................80
Gap Insert Removal & Installation ..................82
Gap Removal ..................................................... 82
Gap Installation ................................................83
TROUBLESHOOTING .........................................84
ELECTRICAL ........................................................87
Electrical Safety Instructions ...........................87
Wiring Overview ................................................ 88
Component Location Index................................89
Electrical Cabinet Wiring ..................................90
Electrical Box ..................................................... 91
Spindle Motor ..................................................... 92
Coolant Pump Motor Wiring ............................. 92
Control Panel Wiring ......................................... 93
Spindle Switches ................................................ 93
Additional Component Wiring .......................... 94
Power Connection .............................................. 94
PARTS ..................................................................95
Headstock Cover ................................................ 95
Headstock Controls ............................................ 96
Headstock Internal Gears ................................. 98
Headstock Transfer Gears ............................... 100
Gearbox Gears .................................................. 101
Gearbox Controls ............................................. 103
Apron Front View ............................................105
Apron Rear View .............................................. 107
Compound Rest & Tool Post ............................ 109
Saddle Top View ..............................................110
Saddle Bottom View.........................................112
Micrometer Stop...............................................113
Dial Indicator ................................................... 113
Bed & Shafts .................................................... 114
End Gears ......................................................... 116
Main Motor ....................................................... 117
Stands & Panels ............................................... 119
Tailstock ........................................................... 121
Steady Rest ......................................................123
Follow Rest ....................................................... 123
Electrical Cabinet & Control Panel ................ 124
Accessories .......................................................125
Front Machine Labels ...................................... 126
Rear & Side Machine Labels ........................... 127
WARRANTY ....................................................... 129
Page 5
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
INTRODUCTION
About This Machine
Foreword
"The screw cutting engine lathe is the oldest and most important of machine tools and from it all other machine tools have been developed. It was the lathe that made possible the building of the steamboat, the locomotive, the electric motor, the automobile and all kinds of machinery used in industry. Without the lathe our great industrial progress of the last century would have been impossible." —How To Run a Lathe, 15th
Edition, South Bend Lathe.
The lathe represented in this manual is a modern day version of the screw cutting lathes that trace their roots back to the 1700's, which were themselves technological improvements of the bow lathe that can be traced back thousands of years to the ancient Egyptians.
Now, almost 300 years later, these modern "screw cutting" lathes are not just a piece of refined machinery, but a culmination of human ingenuity and knowledge embodied into the design and synergy of thousands of interworking parts—some of which represent the life's work and dreams of many inventors, mechanical engineers, and world-class machinists—including the likes of Leonardo da Vinci, Henry Maudsley, and the founders of South Bend Lathe, John and Miles O'Brien.
And now the torch is passed to you—to take the oldest and most important type of machine tool—and carry on the tradition. As the operator of a South Bend Lathe, you now join the ranks of some very famous and important customers, such as Henry Ford, who used the machines he purchased to help him change the world.
Features
These Heavy 13® Gearhead Lathes are packed with standard features and equipment, such as a complete coolant system, easy-to-clean chip drawer, one-shot way lubrication system, included steady and follow rests, chuck guard, adjustable work lamp, foot brake, powered cross feed, 3- and 4-jaw chucks, faceplate, and premium Allen-Bradley contactors, thermal relays, and fuse system.
Spindle speeds are controlled by convenient headstock levers, which allow the operator to quickly set the spindle speed within the available range of 80–2000 RPM.
The beds of these lathes are constructed with Meehanite castings that are hardened and precision-ground in the traditional three V-way prismatic design—long used on South Bend Lathes for its accuracy, durability, and rigidity.
The headstocks feature quick-change gear levers and the carriages include an adjustable clutch that disables automatic carriage feed when it contacts the included feed stop or in the event of a crash.
To further ensure a high degree of accuracy, these lathes are equipped with Japanese spindle bearings. The spindles are D1-5 camlock with an MT#5 taper and 1.57" bore. The tailstocks have an MT#3 taper and 4.5" of quill travel.
Capabilities
This Heavy 13® Gearhead Lathe is built for daily use in a busy industrial setting. Loaded with many nice features and high-precision parts, this lathe excels at making fine tools, dies, thread gauges, jigs, and precision test gauges—however, it is by no means delicate. Thick castings, heavy weight, and quality construction throughout provide the necessary brawn for demanding production and manufacturing tasks.
South Bend Precision Toolroom Lathe
(Circa 1958)
-3-
Page 6
13" Heavy 13® Gearhead Lathe
INTRODUCTION
General Identification
For Machines Mfg. Since 5/11
F
E
A
B
U
T
S
D
C
R
Q
G
P
O
H
I
J
K
L
M
N
Figure 1. Identification.
A. Spindle Speed Levers (see Page 50 for
details)
B. D1-5 Camlock MT#5 Spindle C. 3-Jaw Chuck 8" D. Chuck Guard w/Safety Switch E. Steady Rest F. Follow Rest G. 4-Way Tool Post H. Halogen Work Lamp I. Coolant Nozzle & Valve J. Compound Rest K. Tailstock (see Page 7 for details)
Serious personal injury could occur if you connect the machine to power before completing the setup process. DO NOT connect power until instructed to do so later in this manual.
L. Longitudinal Leadscrew M. Feed Rod N. Coolant Reservoir & Pump Access O. Carriage (see Page 6 for details) P. Safety Foot Brake Q. Chip Drawer R. Micrometer Stop S. Quick-Change Gearbox Controls
(see Page 5 for details)
T. Headstock Feed Direction Lever U. Gearbox Range Lever
Untrained users have an increased risk of seriously injuring themselves with this machine. Do not operate this machine until you have understood this entire manual and received proper training.
-4-
Page 7
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
Controls &
INTRODUCTION
A. Quick-Change Gearbox Levers: Control the
leadscrew and feed rod speed for threading and feed operations.
Components
Refer to Figures 2–6 and the following descriptions to become familiar with the basic controls of this lathe.
Master Power Switch
The rotary switch shown in Figure 2 toggles incoming power ON and OFF to the lathe controls. It also prevents the electrical cabinet door from being opened when the switch is ON.
Master
Power Switch
B. Headstock Feed Direction Lever: Controls
the direction that the leadscrew and feed rod rotate.
C. Gearbox Range Lever: Shifts the quick-
change gearbox into low range, neutral, or high range.
D. Threading and Feed Charts: Display the
necessary configuration of the gearbox levers and end gears for different threading or feeding options.
E. Spindle Speed Lever: Selects one of the four
available spindle speeds within the selected speed range.
F. Spindle Range Lever: Selects the spindle
speed high range (to the left) or the low range (to the right).
Figure 2. Location of the master power switch.
Headstock
F
C
E
B
A
D
Figure 3. Headstock controls.
-5-
Page 8
13" Heavy 13® Gearhead Lathe
INTRODUCTION
For Machines Mfg. Since 5/11
Control Panel
G
Figure 4. Control panel.
G. Power Light: Illuminates when lathe controls
are receiving power.
H. Coolant Pump Switch: Controls the coolant
pump motor.
I. Jog Button: Starts forward spindle rotation
as long as it is pressed.
J. STOP Button: Stops all machine functions.
Twist clockwise to reset.
H
I
J
Carriage
K
L
K. 4-Way Tool Post: Mounts up to four cutting
tools at once that can be individually indexed to the workpiece.
L. Compound Rest Handwheel: Moves the tool
toward and away from the workpiece at the preset angle of the compound rest.
M. One-Shot Oiler: Draws oil from the apron
reservoir to lubricate the carriage ways through various oil ports.
N. Carriage Lock: Secures the carriage in place
when to ensure accuracy during operations where it should not move.
O . Thread Dial and Chart: Dial indicates when
to engage the half nut during inch threading operations. Chart indicates which thread dial reading to engage the half nut for specific inch thread pitches.
P. Spindle Lever: Starts and stops spindle
rotation in either direction.
Q . Half Nut Lever: Engages/disengages the half
nut for threading operations.
R. Apron Feed Direction Knob: Changes
direction of the carriage or the cross slide feed without having to stop the lathe and move the headstock feed direction lever.
S. Feed Selection Lever: Selects the carriage or
cross slide for power feed operations.
-6-
M
N
T. Carriage Handwheel: Moves the carriage
along the bed.
U
O
T
S
Figure 5. Carriage controls.
Q
R
P
U. Cross Slide Handwheel: Moves the cross
slide toward and away from the workpiece.
Page 9
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
INTRODUCTION
Tailstock
V
AA
Z
Figure 6. Tailstock controls.
V. Quill Lock Lever: Secures the quill in
position.
W. Tailstock Lock Lever: Secures the tailstock in
position along the bedway.
W
X
Y
End Gears
Configuring the end gears shown in Figure 7 will control the speed of the leadscrew for threading or the feed rod for power feed operations. The rotational speed of these components depends not only on the end gear configuration, but the spindle speed as well.
End
Gears
Figure 7. End gear components.
X. Quill Handwheel: Moves the quill toward or
away from the spindle.
Y. Gib Adjustment Screw: Adjusts the tapered
gib to control tailstock offset accuracy (1 of 2).
Z. Tailstock Offset Screw: Adjusts the tailstock
offset left or right from the spindle centerline (1 of 2).
AA. Quill: Moves toward and away from the
spindle and holds centers and tooling.
Safety Foot Brake
This lathe is equipped with a foot brake (see Figure 8) to quickly stop the spindle instead of allowing the spindle to coast to a stop on its own. Pushing the foot brake while the spindle is ON cuts power to the motor and stops the spindle.
After the foot brake is used, the spindle lever must be returned to the OFF (middle) position to reset the spindle switches before re-starting spindle rotation.
Spindle
Lever
Foot Brake
Figure 8. Foot brake and spindle lever.
-7-
Page 10
13" Heavy 13® Gearhead Lathe
Product Specifications
INTRODUCTION
For Machines Mfg. Since 5/11
Product Specifications
P.O. Box 2027, Bellingham, WA 98227 U.S.A.
0(/.%s© South Bend Lathe Co.
www.southbendlathe.com
MODEL SB1049 & SB1050
®
13" HEAVY 13
Model Number SB1049 SB1050
Product Dimensions
Weight 1870 lbs. 2205 lbs.
Width (side-to-side)/Depth (front-to-back)/Height
Foot Print (Width/Depth) 69
Shipping Dimensions
Type Wood Slat Crate
Weight 2090 lbs. 2469 lbs.
Width (side-to-side)/Depth (front-to-back)/Height
Electrical
Power Requirement 220V, Single-Phase, 60Hz
Full-Load Current Rating 19.5A
Minimum Circuit Size 30A
Switch Magnetic with Thermal Protection
Switch Voltage 220V
Plug Included No
Recommended Plug/Outlet Type NEMA L6-30
GEARHEAD LATHES
79" x 38" x 69" 90" x 38" x 69"
3
⁄4" x 19 1⁄2" 80 3⁄4" x 19 1⁄2"
79 x 38 x 69 79" x 45" x 69"
-8-
Page 11
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
INTRODUCTION
Model Number SB1049 SB1050
Main Motor
Type TEFC Induction
Horsepower 3 HP
Voltage 220V
Phase Single-Phase
Amps 19A
Speed 1720
Cycle 60 Hz
Power Transfer V-Belt & Gear
Bearings Shielded & Permanently Sealed
Coolant Motor
Type TEFC Induction
1
Horsepower
Voltage 220V
Phase Single-Phase
Amps 0.45A
Speed 3450 RPM
Cycle 60 Hz
Power Transfer Direct Drive
Bearings Shielded & Permanently Sealed Shielded & Permanently Sealed
Operation Information
Swing Over Bed 13.38"
Distance Between Centers 30" 40"
Swing Over Cross Slide 8.26"
Swing Over Saddle 11.02"
Swing Over Gap N/A 20"
Maximum Tool Bit Size 0.75"
Compound Travel 4"
Carriage Travel 36.5"
Cross Slide Travel 7"
⁄8 HP
-9-
Page 12
13" Heavy 13® Gearhead Lathe
INTRODUCTION
For Machines Mfg. Since 5/11
Model Number SB1049 SB1050
Headstock Information
Spindle Bore 1.57"
Spindle Taper MT#5
Number of Spindle Speeds 8
Range of Spindle Speeds 80–2000 RPM
Spindle Type D1-5 Camlock
Spindle Bearings Tapered Roller
Tailstock Information
Tailstock Quill Travel 4.5"
Tailstock Taper MT#3
Tailstock Barrel Diameter 1.968"
Threading Information
Number of Longitudinal Feeds 17
Range of Longitudinal Feeds 0.002"–0.067"
Number of Cross Feeds 17
Range of Cross Feeds 0.001"–0.034"
Number of Inch Threads 45
Range of Inch Threads 2–72 TPI
Number of Metric Threads 39
Range of Metric Threads 0.2–14 mm
Number of Modular Pitches 18
Range of Modular Pitches 0.3–3.5 MP
Number of Diametral Pitches 21
Range of Diametral Pitches 8–44 DP
Dimensions
Bed Width 9"
1
Leadscrew Diameter 1
Leadscrew TPI 4 TPI
Leadscrew Length 47" 59"
Steady Rest Capacity
Follow Rest Capacity
Faceplate Size 10"
Feed Rod Diameter
Floor to Center Height 42.2"
Height With Leveling Jacks 59.06"
⁄8"
5
⁄16"–4 5⁄16"
5
⁄8"–3 1⁄8"
3
⁄4"
-10-
Page 13
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
INTRODUCTION
Model Number SB1049 SB1050
Construction
Headstock Cast Iron
Headstock Gears Flame-Hardened Steel
Bed Meehanite Castings with Precision Hardened-and-Ground Ways
Stand Cast Iron
Paint Urethane
Other
Country of Origin Taiwan (Some Components Made in USA & Japan)
Warranty 1 Year
Serial Number Location ID Label on Front of Headstock
1
Assembly Time Approximately 1
Sound Rating at Idle 71 dB
⁄2 Hours
-11-
Page 14
13" Heavy 13® Gearhead Lathe
SAFETY
For Machines Mfg. Since 5/11
Understanding Risks of Machinery
Operating all machinery and machining equipment can be dangerous or relatively safe depending on how it is installed and maintained, and the operator's experience, common sense, risk awareness, working conditions, and use of personal protective equipment (safety glasses, respirators, etc.).
The owner of this machinery or equipment is ultimately responsible for its safe use. This responsibility includes proper installation in a safe environment, personnel training and usage authorization, regular inspection and maintenance, manual availability and comprehension, application of safety devices, integrity of cutting tools or accessories, and the usage of approved personal protective equipment by all operators and bystanders.
The manufacturer of this machinery or equipment will not be held liable for injury or property damage from negligence, improper training, machine modifications, or misuse. Failure to read, understand, and follow the manual and safety labels may result in serious personal injury, including amputation, broken bones, electrocution, or death.
The signals used in this manual to identify hazard levels are as follows:
Death or catastrophic harm WILL occur.
Death or catastrophic harm COULD occur.
Basic Machine Safety
Owner’s Manual: All machinery and machining
equipment presents serious injury hazards to untrained users. To reduce the risk of injury, anyone who uses THIS item MUST read and understand this entire manual before starting.
Personal Protective Equipment:
servicing this item may expose the user to flying debris, dust, smoke, dangerous chemicals, or loud noises. These hazards can result in eye injury, blindness, long­term respiratory damage, poisoning, cancer, reproductive harm or hearing loss. Reduce your risks from these hazards by wearing approved eye protection, respirator, gloves, or hearing protection.
Operating or
Moderate injury or fire MAY occur.
Machine or property damage may occur.
Trained/Supervised Operators Only: Untrained
users can seriously injure themselves or bystanders. Only allow trained and properly supervised personnel to operate this item. Make sure safe operation instructions are clearly understood. If electrically powered, use padlocks and master switches, and remove start switch keys to prevent unauthorized use or accidental starting.
Guards/Covers:
moving parts during operation may cause severe entanglement, impact, cutting, or crushing injuries. Reduce this risk by keeping any included guards/covers/doors installed, fully functional, and positioned for maximum protection.
Accidental contact with
-12-
Page 15
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
SAFETY
Entanglement: Loose clothing, gloves, neckties,
jewelry or long hair may get caught in moving parts, causing entanglement, amputation, crushing, or strangulation. Reduce this risk by removing/securing these items so they cannot contact moving parts.
Mental Alertness: Operating this item with
reduced mental alertness increases the risk of accidental injury. Do not let a temporary influence or distraction lead to a permanent disability! Never operate when under the influence of drugs/alcohol, when tired, or otherwise distracted.
Safe Environment:
powered equipment in a wet environment may result in electrocution; operating near highly flammable materials may result in a fire or explosion. Only operate this item in a dry location that is free from flammable materials.
Electrical Connection: With electically powered
equipment, improper connections to the power source may result in electrocution or fire. Always adhere to all electrical requirements and applicable codes when connecting to the power source. Have all work inspected by a qualified electrician to minimize risk.
Disconnect Power: Adjusting or servicing
electrically powered equipment while it is connected to the power source greatly increases the risk of injury from accidental startup. Always disconnect power BEFORE any service or adjustments, including changing blades or other tooling.
Operating electrically
Chuck Keys or Adjusting Tools:
adjust spindles, chucks, or any moving/ rotating parts will become dangerous projectiles if left in place when the machine is started. Reduce this risk by developing the habit of always removing these tools immediately after using them.
Work Area:
the risks of accidental injury. Only operate this item in a clean, non-glaring, and well­lighted work area.
Properly Functioning Equipment:
maintained, damaged, or malfunctioning equipment has higher risks of causing serious personal injury compared to those that are properly maintained. To reduce this risk, always maintain this item to the highest standards and promptly repair/service a damaged or malfunctioning component. Always follow the maintenance instructions included in this documentation.
Unattended Operation:
equipment that is left unattended while running cannot be controlled and is dangerous to bystanders. Always turn the power OFF before walking away.
Health Hazards: Certain cutting fluids and
lubricants, or dust/smoke created when cutting, may contain chemicals known to the State of California to cause cancer, respiratory problems, birth defects, or other reproductive harm. Minimize exposure to these chemicals by wearing approved personal protective equipment and operating in a well ventilated area.
Clutter and dark shadows increase
Electrically powered
Tools used to
Poorly
Secure Workpiece/Tooling:
cutting tools, or rotating spindles can become dangerous projectiles if not secured or if they hit another object during operation. Reduce the risk of this hazard by verifying that all fastening devices are properly secured and items attached to spindles have enough clearance to safely rotate.
Loose workpieces,
Difficult Operations:
operations with which you are unfamiliar increases the risk of injury. If you experience difficulties performing the intended operation, STOP! Seek an alternative method to accomplish the same task, ask a qualified expert how the operation should be performed, or contact our Technical Support for assistance.
Attempting difficult
-13 -
Page 16
13" Heavy 13® Gearhead Lathe
SAFETY
Additional Metal Lathe Safety
For Machines Mfg. Since 5/11
Speed Rates. Operating the lathe at the wrong
speed can cause nearby parts to break or the workpiece to come loose, which will result in dangerous projectiles that could cause severe impact injuries. Large or non-concentric workpieces must be turned at slow speeds. Always use the appropriate feed and speed rates.
Chuck Key Safety. A chuck key left in the chuck
can become a deadly projectile when the spindle is started. Always remove the chuck key after using it. Develop a habit of not taking your hand off of a chuck key unless it is away from the machine.
Safe Clearances. Workpieces that crash into
other components on the lathe may throw dangerous projectiles in all directions, leading to impact injury and damaged equipment. Before starting the spindle, make sure the workpiece has adequate clearance by hand-rotating it through its entire range of motion. Also, check the tool and tool post clearance, chuck clearance, and saddle clearance.
Clearing Chips. Metal chips can easily cut bare
skin—even through a piece of cloth. Avoid clearing chips by hand or with a rag.Use a brush or vacuum to clear metal chips.
Stopping Spindle by Hand. Stopping the spindle
by putting your hand on the workpiece or chuck creates an extreme risk of entanglement, impact, crushing, friction, or cutting hazards. Never attempt to slow or stop the lathe spindle with your hand. Allow the spindle to come to a stop on its own or use the brake.
Crashes. Aggressively driving the cutting tool
or other lathe components into the chuck may cause an explosion of metal fragments, which can result in severe impact injuries and major damage to the lathe. Reduce this risk by releasing automatic feeds after use, not leaving lathe unattended during operation, and checking clearances before starting the lathe. Make sure no part of the tool, tool holder, compound rest, cross slide, or carriage will contact the chuck during operation.
Long Stock Safety. Long stock can whip violently
if not properly supported, causing serious impact injury and damage to the lathe. Reduce this risk by supporting any stock that extends from the chuck/headstock more than three times its own diameter. Always turn long stock at slow speeds.
Securing Workpiece. An improperly secured
workpiece can fly off the lathe spindle with deadly force, which can result in a severe impact injury. Make sure the workpiece is properly secured in the chuck or faceplate before starting the lathe.
Chucks. Chucks are very heavy and difficult to
grasp, which can lead to crushed fingers or hands if mishandled. Get assistance when handling chucks to reduce this risk. Protect your hands and the precision-ground ways by using a chuck cradle or piece of plywood over the ways of the lathe when servicing chucks. Use lifting devices when necessary.
Coolant Safety. Coolant is a very poisonous
biohazard that can cause personal injury from skin contact alone, especially when it gets old or has been well-used. Incorrectly positioned coolant nozzles can splash on the operator or the floor, resulting in skin exposure or a slipping hazard. To decrease your risk, change coolant regularly and position the nozzle where it will not splash or end up on the floor.
Tool Selection. Cutting with an incorrect or
dull tool increases the risk of accidental injury due to the extra force required for the operation, which increases the risk of breaking or dislodging components that can cause small shards of metal to become dangerous projectiles. Always select the right cutter for the job and make sure it is sharp. Using a correct, sharp tool decreases strain and provides a better finish.
-14-
Page 17
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
SAFETY
Additional Chuck Safety
Entanglement. Entanglement with a rotating
chuck can lead to death, amputation, broken bones, or other serious injury. Never attempt to slow or stop the lathe chuck by hand, and always roll up long sleeves, tie back long hair, and remove any jewelry or loose apparel BEFORE operating.
Chuck Speed Rating. Excessive spindle speeds
greatly increase the risk of the workpiece or chuck being thrown from the machine with deadly force. Never use spindle speeds faster than the chuck RPM rating or the safe limits of your workpiece.
Using Correct Equipment. Many workpieces can
only be safely turned in a lathe if additional support equipment, such as a tailstock or steady rest, is used. If the operation is too hazardous to be completed with the lathe or existing equipment, the operator must have enough experience to know when to use a different machine or find a safer way. If you do not have this experience, seek additional training (outside of this manual) from experienced lathe operators, books, or formal classes
Trained Operators Only. Using a chuck
incorrectly can result in workpieces coming loose at high speeds and striking the operator or bystanders with deadly force. To reduce the risk of this hazard, read and understand this document and seek additional training from an experienced chuck user before using a chuck.
Chuck Capacity. Avoid exceeding the capacity
of the chuck by clamping an oversized workpiece. If the workpiece is too large to safely clamp with the chuck, use a faceplate or a larger chuck if possible. Otherwise, the workpiece could be thrown from the lathe during operation, resulting in serious impact injury or death.
Clamping Force. Inadequate clamping force
can lead to the workpiece being thrown from the chuck and striking the operator or bystanders. Maximum clamping force is achieved when the chuck is properly maintained and lubricated, all jaws are fully engaged with the workpiece, and the maximum chuck clamping diameter is not exceeded.
Proper Maintenance.
maintained and lubricated to achieve maximum clamping force and withstand the rigors of centrifugal force. To reduce the risk of a thrown workpiece, follow all maintenance intervals and instructions in this document.
Disconnect Power. Serious entanglement or
impact injuries could occur if the lathe is started while you are adjusting, servicing, or installing the chuck. Always disconnect the lathe from power before performing these procedures.
All chucks must be properly
-15 -
Page 18
13" Heavy 13® Gearhead Lathe
PREPARATION
For Machines Mfg. Since 5/11
Preparation Overview Things You'll Need
The purpose of the preparation section is to help you prepare your machine for operation. The list below outlines this basic process. Specific steps for each of these points will be covered in detail later in this section.
The typical preparation process is as follows:
1. Unpack the lathe and inventory the contents
of the box/crate.
2. Clean the lathe and its components.
3. Identify an acceptable location for the lathe
and move it to that location.
4. Level the lathe and either bolt it to the floor
or place it on mounts.
5. Assemble the loose components and make
any necessary adjustments or inspections to ensure the lathe is ready for operation.
6. Check/lubricate the lathe.
To complete the preparation process, you will need the following items:
For Lifting and Moving
s !FORKLIFTOROTHERPOWERLIFTINGDEVICE
rated for at least 25% more than the shipping weight of the lathe (see Product Specifications beginning on Page 1)
s ,IFTINGstraps, each rated for at least 25%
more than the shipping weight of the lathe
s 'UIDERODSFORSTEADINGTHELOADWHENLIFTING s Two other people for assistance when moving
machine
s Hardwood blocks (see Page 22)
For Power Connection
s !POWERSOURCETHATMEETSTHEMINIMUM
circuit requirements for this machine (review Power Supply Requirements on the next page for details)
s !NELECTRICIANORQUALIFIEDSERVICEPERSONNEL
to ensure a safe and code-compliant connection to the power source
7. Connect the lathe to the power source.
8. Test run the lathe to make sure it functions
properly.
9. Perform the spindle break-in procedure to prepare the lathe for operation.
For Cleaning & Assembly
s Cotton rags s Mineral spirits s Quality metal protectant oil s 3AFETYglasses s Wrench or socket 21mm s Wrench or socket 19mm s &LOORmounting hardware as needed s 0RECISIONLEVEL s Standard screwdriver #2
-16 -
Page 19
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
A
Power Supply Requirements
PREPARATION
The full-load current is not the maximum amount of amps that the machine will draw. If the machine is overloaded, it will draw additional amps beyond the full-load rating.
Availability
Before installing the machine, consider the availability and proximity of the required power supply circuit. If an existing circuit does not meet the requirements for this machine, a new circuit must be installed.
To minimize the risk of electrocution, fire, or equipment damage, installation work and electrical wiring must be done by an electrician or qualified service personnel in accordance with all applicable codes.
Serious injury could occur if you connect the machine to power before completing the setup process. DO NOT connect to power until instructed later in this manual.
Full-Load Current Rating
The full-load current rating is the amperage a machine draws at 100% of the rated output power. On machines with multiple motors, this is the amperage drawn by the largest motor or sum of all motors and electrical devices that might operate at one time during normal operations.
If the machine is overloaded for a sufficient length of time, damage, overheating, or fire may result—especially if connected to an undersized circuit. To reduce the risk of these hazards, avoid overloading the machine during operation and make sure it is connected to a power supply circuit that meets the requirements in the following section.
Circuit Requirements
This machine is prewired to operate on a 220V power supply circuit that has a verified ground and meets the following requirements:
Nominal Voltage ...............................220V/240V
Cycle .............................................................60 Hz
Phase ..............................................Single-Phase
Circuit Rating....................................... 30 Amps
Cord ........."S" Type, 3-Wire, 12 AWG, 300 VAC
Plug/Receptacle ............................NEMA L6-30
power supply circuit includes all electrical equipment between the main breaker box or fuse panel in your building and the incoming power connections inside the machine. This circuit must be safely sized to handle the full-load current that may be drawn from the machine for an extended period of time. (If this machine is
SB1049 Full-Load Rating ................ 19.5 Amps
SB1050 Full-Load Rating ................ 19.5 Amps
For your own safety and protection of property, consult an electrician if you are unsure about wiring practices or applicable electrical codes.
Note: The circuit requirements in this manual are for a dedicated circuit—where only one machine will be running at a time. If this machine will be connected to a shared circuit where multiple machines will be running at the same time, consult a qualified electrician to ensure the circuit is properly sized.
-17-
Page 20
13" Heavy 13® Gearhead Lathe
PREPARATION
This machine must be grounded! In the event of certain types of malfunctions or breakdowns, grounding provides a path of least resistance for electric current in order to reduce the risk of electric shock.
Improper connection of the equipment-grounding wire can result in a risk of electric shock. The wire with green insulation (with or without yellow stripes) is the equipment-grounding wire. If repair or replacement of the power cord is necessary, do not connect the equipment­grounding wire to a live (current carrying) terminal.
Check with an electrician or qualified service personnel if you do not understand these grounding requirements, or if you are in doubt about whether the machine is properly grounded. If you ever notice that a cord is damaged or worn, disconnect it from power, and immediately replace it with a new one.
For Machines Mfg. Since 5/11
Extension CordsGrounding Requirements
We do not recommend using an extension cord with this machine. If you must use an extension cord, only use it if absolutely necessary and only on a temporary basis.
Extension cords cause voltage drop, which may damage electrical components and shorten motor life. Voltage drop increases as the extension cord size gets longer and the gauge size get smaller (higher gauge numbers indicate smaller sizes).
Any extension cord used with this machine must contain a ground wire, match the required plug and receptacle, and meet the following requirements:
Minimum Gauge Size ...............................12 AWG
Maximum Length (Shorter is Better) ........... 50 ft.
The power cord and plug specified under Circuit Requirements section on the previous page has an equipment-grounding wire and a grounding prong. The plug must only be inserted into a matching receptacle (outlet) that is properly installed and grounded in accordance with all local codes and ordinances (see Figure 9).
GROUNDED
L6-30 LOCKING
RECEPTACLE
Grounding Prong
is Hooked
L6-30
LOCKING
PLUG
Current Carrying Prongs
Figure 9. Typical NEMA L6-30 plug and receptacle.
-18 -
Page 21
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
PREPARATION
Unpacking
This item was carefully packaged to prevent damage during transport. If you discover any damage, please immediately call Customer Service at (360) 734-1540 for advice. You may need to file a freight claim, so save the containers and all packing materials for possible inspection by the carrier or its agent.
Inventory
Main Inventory 1: (Figure 10) Qty
A. Steady Rest Assembly (Installed) .................1
B. 10" Faceplate w/D1-5 Camlock Stud Set ...... 1
C. 8" 4-Jaw Chuck w/Combo Jaws (SB1226) ....1
D. 3-Jaw Chuck Key ...........................................1
E. 4-Jaw Chuck Key ........................................... 1
F. Follow Rest Assembly (Installed) .................. 1
Tool Box Inventory: (Figure 11) Qty
G. Tool Box .......................................................... 1
H. Open End Wrench 22/24mm .........................1
I. Open End Wrench 14/17mm .........................1
J. Open End Wrench 10/12mm .........................1
K. Phillips Screwdriver #2 .................................1
L. Standard Screwdriver #2 ............................... 1
M. Hex Wrench 8mm ..........................................1
N. Tapered Spindle Sleeve MT#5-#3 .................1
O. Dead Center MT#3 .........................................1
P. Carbide-Tipped Dead Center MT#3 .............. 1
Q. Camlock Key D1-5 ......................................... 1
R. Tool Post T-Wrench (Clamped on Tool Post) 1
S. Hex Wrench Set 1.5-10mm ............................ 1
T. Carriage Handwheel Handle .........................1
U. Cross Slide Handwheel Handle ..................... 1
V. Cast Iron Leveling Pads ................................6
A
D
F
E
Figure 10. Main inventory.
G
Q
R
If you cannot find an item on this list, check the mounting location on the machine or the packaging materials. Sometimes parts are pre-installed for shipping, or they become hidden by packaging materials.
T
S
Figure 11. Toolbox inventory.
H
N
O
U
B
C
I
J
P
K
L
M
V
Pre-Installed (Not Shown) Qty
s 7" 3-Jaw Chuck (SB1308) .............................. 1
1
s 8
Note: Some inventory components may be shipped inside of the lathe electrical box. These items MUST be removed before connecting the lathe to the power source.
⁄4" Back Plate D1-5 (SB1399) ...................... 1
-19 -
Page 22
13" Heavy 13® Gearhead Lathe
A
PREPARATION
Cleaning & Protecting
For Machines Mfg. Since 5/11
The unpainted surfaces are coated at the factory with a heavy-duty rust preventative that prevents corrosion during shipment and storage. The benefit of this rust preventative is that it works very well. The downside is that it can be time-consuming to thoroughly remove.
Be patient and do a careful job when cleaning and removing the rust preventative. The time you spend doing this will reward you with smooth-sliding parts and a better appreciation for the proper care of the unpainted surfaces.
lthough there are many ways to successfully remove the rust preventative, the following process works well in most situations.
Before cleaning, gather the following:
s $ISPOSABLErags s #LEANERDEGREASER (certain citrus-based
degreasers work extremely well and they have non-toxic fumes)
s 3AFETYGLASSESDISPOSABLEGLOVES
Note: Automotive degreasers, mineral spirits, or
7$sCANBEUSEDTOREMOVERUSTPREVENTATIVE
Before using these products, though, test them on an inconspicuous area of a painted surface to make sure they will not damage it.
Avoid chlorine-based solvents, such as acetone or brake parts cleaner that may damage painted surfaces. Always follow the manufacturer’s instructions when using any type of cleaning product.
Basic steps for removing rust preventative:
1. Put on safety glasses and disposable gloves.
2. #OATALLSURFACESTHATHAVERUSTPREVENTATIVE
with a liberal amount of your cleaner or degreaser and let them soak for a few minutes.
3. Wipe off the surfaces. If your cleaner or
degreaser is effective, the rust preventative will wipe off easily.
Note: To clean off thick coats of rust preventative
on flat surfaces, such as beds or tables, use
A0,!34)#PAINTSCRAPERTOSCRAPEOFFTHE
majority of the coating before wiping it off
WITHYOURRAG$ONOTUSEAMETALSCRAPEROR
it may scratch the surface.)
4. Repeat Steps 2–3 as necessary until clean,
then coat all unpainted surfaces with a quality metal protectant or light oil to prevent rust.
-20-
GAS
Gasoline and petroleum products have low flash points and can explode or cause fire if used for cleaning. Avoid using these products to remove rust preventative.
Many cleaning solvents are toxic if inhaled. Minimize your risk by only using these products in a well ventilated area.
Remove the end gear cover and end gears, and use a stiff brush with mineral spirits to clean the rust preventative from the gears and shafts. DO NOT get any cleaner or rust preventative on the V-belts, as it could damage them or make them slip during operations. If the belts do become contaminated, replace them.
Page 23
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
PREPARATION
LocationLocation
Physical Environment
The physical environment where your machine is operated is important for safe operation and longevity of parts. For best results, operate this machine in a dry environment that is free from excessive moisture, hazardous or flammable chemicals, airborne abrasives, or extreme conditions. Extreme conditions for this type of machinery are generally those where the ambient temperature is outside the range of 41°– 104°F; the relative humidity is outside the range of 20–95% (non-condensing); or the environment is subject to vibration, shocks, or bumps.
Electrical Installation
Place this machine near an existing power source that meets the minimum circuit requirements. Make sure all power cords are protected from traffic, material handling, moisture, chemicals, or other hazards. Leave access to disconnect the power source or engage a lockout/tagout device.
Weight Load
Refer to the Machine Specifications for the weight of your machine. Make sure that the surface upon which the machine is placed will bear the weight of the machine, additional equipment that may be installed on the machine, and the heaviest workpiece that will be used. Additionally, consider the weight of the operator and any dynamic loading that may occur when operating the machine.
Space Allocation
Consider the largest size of workpiece that will be processed through this machine and provide enough space around the machine for adequate operator material handling or the installation of auxiliary equipment. With permanent installations, leave enough space around the machine to open or remove doors/covers as required by the maintenance and service described in this manual.
Lighting
Lighting around the machine must be adequate enough that operations can be performed safely. Shadows, glare, or strobe effects that may distract or impede the operator must be eliminated.
Wall
Electrical
Min. 30"
for Maintenance
Keep
Workpiece Loading Area Unobstructed
Cabinet
Lathe
Children or untrained people may be seriously injured by this machine. Install machine in an access restricted location.
54"
38"
(Drawing Not To Scale)
Figure 12. Space required for full range of movement.
79" (SB1049)
90" (SB1050)
-21-
Page 24
13" Heavy 13® Gearhead Lathe
Lifting & Moving
PREPARATION
5. Position hardwood blocks under each end
of the bed as shown in Figure 13. This will keep the lifting straps away from the leadscrew, feed rod, and spindle rod to prevent bending them during lifting.
(Looking at Lifting Setup from Tailstock End)
Leadscrew
Feed Rod
For Machines Mfg. Since 5/11
To Power Lifting Equipment
Control
Rod
Lifting Strap
Lathe
Bed
This machine and its parts are heavy! Serious personal injury may occur if safe moving methods are not used. To reduce the risk of a lifting or dropping injury, ask others for help, and use power equipment and guide rods.
Do not attempt to lift or move this lathe without using the proper lifting equipment (such as forklift or crane) or the necessary assistance from other people. Each piece of lifting equipment must be rated for at least 25% more than the shipping weight of your lathe to support dynamic loads that may be applied while lifting. Refer to Things You'll Need on Page 16 for details.
To lift and move the lathe:
1. Remove the shipping crate top and sides,
then remove the small components from the shipping pallet.
2. Move the lathe to its prepared location while
it is still attached to the shipping pallet.
Hardwood Blocks
and Planks
Positioned as
Required to
Prevent Lifting
Straps from
Bending
Leadscrew
Figure 13. Lifting setup to keep straps from bending
leadscrew or rods.
Note: Fasten a center support between the
hardwood blocks so that they will stay spread apart and in place when lifting (see the example in Figure 14).
Center
Support
3. Unbolt the lathe from the shipping pallet
4. To balance the load for lifting, move the
tailstock and carriage to the extreme right end of the bedway, then lock them in place.
Note: Before attempting to move the carriage,
make sure the carriage lock is loose, the half nut is disengaged, and the power feed is disengaged (feed selection lever).
-22-
Hardwood
Blocking
Figure 14. Example of blocking center support.
Page 25
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
PREPARATION
6. Attach the lifting straps to the power lifting
equipment (see Figure 15 for an example).
Leveling & Mounting
You must level your machine and either use
Use Blocks as Necessary to Space Straps Away from Control Rod, Feed Rod, and Leadscrew to Prevent Bending when the Lathe is Lifted
Power Lifting
Equipment
Lifting Straps
the included foot pads and leveling hardware or bolt and shim your lathe to the floor. Because mounting your lathe to the floor with permanent hardware is an optional step and floor materials may vary, floor mounting hardware is not included.
Leveling
Hardwood Blocking
Figure 15. Example of lathe setup for lifting.
Hardwood Blocking
7. At each end of the lathe, have assistants
connect guide rods to safely keep the lathe from swaying or tipping during lifting.
When lifting the lathe with straps, the load will be top heavy. Take extra care to keep the load balanced vertically and only lift the lathe far enough to remove the shipping pallet.
8. Raise the lathe a couple of inches and check
the balance of the load.
— If the load is not safely balanced,
immediately lower the lathe and resolve the issue before attempting to lift it again.
For accurate turning results and to prevent warping the cast iron bed and ways, the lathe bedways MUST be leveled from side-to-side and from front-to-back on both ends.
Re-check the bedways 24 hours after installation, two weeks after that, and then annually to make sure they remain level.
Leveling machinery helps precision components, such as bedways, remain straight and flat during the lifespan of the machine. Components on a machine that is not level may slowly twist due to the dynamic loads placed on the machine during operation.
For best results, use a precision level that is at least 12" long and sensitive enough to show a distinct movement when a 0.003" shim (approximately the thickness of one sheet of standard newspaper) is placed under one end of the level.
9. Raise the lathe enough to clear the shipping
pallet, carefully remove the pallet, then lower the lathe into position.
See the figure below for an example of a high precision level.
Figure 16. Example of a precision level.
-23-
Page 26
13" Heavy 13® Gearhead Lathe
PREPARATION
To level the machine, use a precision level to make sure the bedways are level from side-to­side and from front-to-back.
— If using the included leveling pads (see
Figure 17), place them under the six leveling jack bolt locations, then adjust the bolts to level the lathe.
Jack Bolts
Pads
Figure 17. Leveling pads and screws.
— If using mounting hardware that does not
allow for adjustment, level the lathe by placing metal shims between the lathe base and the floor before bolting it down.
For Machines Mfg. Since 5/11
Assembly
With the exception of the handwheel handles, the lathe is shipped fully assembled.
To install the handwheel handles, thread the large handle into the carriage handwheel and the small handle into the cross slide handwheel, as shown in Figure 19.
Handwheel
Handles
Figure 19. Handwheel handles installed.
Bolting to Concrete Floors
Lag screws and anchors, or anchor studs (below), are two popular methods for bolting machinery to a concrete floor. We suggest you research the many options and methods for mounting your machine and choose the best one for your specific application.
Anchor
Stud
Lag Screw
and Anchor
Figure 18. Common types of fasteners for bolting
machinery to concrete floors.
Most electrical codes require that machines connected to the power source by fixed conduit MUST be secured to the floor.
Lubricating Lathe
GEARBOXES MUST
BE FILLED WITH OIL!
OIL MAY NOT BE
SHIPPED WITH MACHINE!
Refer to Lubrication Section
for Correct Oil Type.
The headstock, quick-change gearbox, and apron oil reservoirs must have the proper amount of oil in them before the lathe can be operated for the first time.
Damage caused to the bearings and gears from running the lathe without oil in the reservoirs will not be covered under warranty. Refer to the Lubrication section, beginning on Page 66, for details on how to check, add oil, and prime the headstock oil pump.
-24-
Page 27
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
PREPARATION
In addition to the reservoirs, we also recommend that you lubricate all other points on the machine at this time. This can be accomplished by following the maintenance schedule on Page 64.
Note: If this lathe was shipped with oil in the reservoirs, do not change that oil until after the test run and spindle break-in procedures.
Adding Coolant
Add the coolant of your choice now. For detailed instructions on where the coolant tank is located and how to add fluid, refer to Coolant System Service on Page 71.
Power Connection
2. Thread the power cord through the strain
relief, and up to the master power switch shown in Figure 20.
Incoming
Power
Strain Relief
Master
Power
Switch
Electrocution or fire may occur if machine is ungrounded, incorrectly connected to power, or connected to an undersized circuit. Use an electrician or a qualified service personnel to ensure a safe power connection.
Once your machine is set up and assembled as previously described in this manual, it is ready to be connected to the power source.
Note About Extension Cords: Using an incorrectly sized extension cord may decrease the life of electrical components on your machine. Refer to Extension Cords on Page 18 for more information.
To connect the power cord to the lathe:
1. Make sure the master power switch is
turned to the OFF position, then open the electrical cabinet door.
Figure 20. Location to connect power inside main
electrical cabinet.
3. Connect the incoming hot wires to the
upper master power switch terminals, as illustrated in Figure 21.
To Plug
HotHot
Master
Power
Switch
Figure 21. Power connection at master power switch.
Ground
4. Connect the incoming ground wire to the
ground terminal on the switch bracket, as illustrated in Figure 21.
-25-
Page 28
13" Heavy 13® Gearhead Lathe
5. Make sure the power cord and wires have
slack between the strain relief and terminal connections so that they do not bind, then tighten the strain relief to secure the cord.
Note: The strain relief must be tightened against
the outer jacket of the cord. Avoid over­tightening the strain relief or it may crush the cord and cause a short.
PREPARATION
For Machines Mfg. Since 5/11
Test Run
After all preparation steps have been completed, the machine and its safety features must be tested to ensure correct operation. If you discover a problem with the operation of the machine or its safety components, shut the machine down, disconnect it from power, and do not operate it until you have resolved the problem.
6. Test the strain relief to ensure it is properly
tightened by pulling the cord from outside the box with light-to-moderate force. When the strain relief is properly tightened, the cord will not move inside the cabinet.
7. Install a NEMA L6-30 plug on the other end
of the power cord per the manufacturer's instructions.
8. Close and lock the main electrical box door.
9. Connect the plug to the matching receptacle
and power source as specified in Circuit Requirements on Page 17.
To avoid unexpected start-up of lathe components, keep the master power switch turned OFF until instructed otherwise in the Test Run.
A Troubleshooting section is provided, starting on Page 84, to assist you with solutions if a problem occurs or if the lathe does not function as described in this section.
If you need additional help after reviewing the troubleshooting section, or you are not confident troubleshooting the machine on your own, contact our Tech Support at (360) 734-1540.
To test run your machine:
1. Make sure the master power switch (see
Figure 22) on the rear of the machine is turned OFF.
Main Power
Switch
-26-
Figure 22. Location of the master power switch.
2. Read and follow the safety instructions
at the beginning of the manual, take all required safety precautions, and make sure all previous preparation steps discussed in this manual have been followed and completed.
Page 29
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
PREPARATION
3. Clear away all tools and objects used during
assembly, lubrication, and preparation.
4. Make sure that the chuck and jaws, if
installed, are secure (refer to Chuck and Faceplate Mounting on Page 32).
Note: If a chuck is not installed on the lathe, you
do not need to install one for this test.
5. Push the STOP button on the control panel
(see Figure 23), and point the coolant nozzle into the chip pan.
Power
Light
Note: During the next step, you may need to
use the chuck key rock the spindle back and forth while attempting to shift so the gears will mesh. If you do this, be sure to remove the chuck key afterward.
7. Set the spindle speed to 80 RPM as follows:
a. Move the spindle range lever so the
arrow on the hub points toward the L (low) label (see Figure 25).
Speed
Lever
Spindle Range
Lever
Coolant
Pump
Switch
Figure 23. Control panel.
Jog
Button
STOP
Button
6. Disengage the quick-change gearbox
by moving the feed range lever to the neutral (middle) position, as illustrated in Figure 24.
Feed
Range Lever
Feed Range Lever
Low
:>
Spindle Speed
*
*
"
*
&
"
$
%
"
"
"
$
)
)
$
#
$
)
#
$
"
&
"
'
$
Lever Set to
80 RPM
Spindle Range
Lever Set to LOW
Figure 25. Spindle speed set to 80 RPM.
b. Move the spindle speed lever so that the
80 on its hub is also pointing at the L
label.
Note: You will hear a distinct click when
the spindle speed lever is in the correct position.
Neutral
High
Figure 24. Feed range lever.
-27-
Page 30
13" Heavy 13® Gearhead Lathe
PREPARATION
For Machines Mfg. Since 5/11
8. Turn the master power switch on the
electrical cabinet to the ON position.
9. Reset the STOP button by twisting it
clockwise until it pops out. The power lamp on the control panel should illuminate.
10. To ensure the carriage components do not
unexpectedly move during the following steps, disengage the half nut lever and feed selection lever (see Figure 26).
Half Nut
Lever
Feed
Selection
Lever
Spindle
Lever
Disengaged
Cross Slide
Disengaged
Carriage
Halfnut
Lever
Feed Control
Lever
Engaged
— When operating correctly, the machine
runs smoothly with little or no vibration or rubbing noises.
— Investigate and correct strange or
unusual noises or vibrations before operating the machine further. Always disconnect the machine from power when investigating or correcting potential problems.
12. Press the STOP button to turn the lathe
OFF, then, without resetting the STOP button, try to restart spindle rotation. The spindle should not start.
— If spindle rotation does start with the
STOP button pressed in, the STOP button safety is not operating correctly. This safety feature must operate properly before continuing operation. Use the spindle lever to stop the lathe, disconnect it from power, and call Tech Support for help.
13. Move the spindle lever to the OFF (middle)
position, reset the STOP button by twisting it clockwise until it pops out, then restart spindle rotation.
Figure 26. Disengaging carriage components.
11. Start the spindle by pulling the spindle lever
out and moving it down (see Figure 27).
Spindle
Lever
Figure 27. Spindle lever in down (forward) position.
14. Push the foot brake. The spindle should
come to a quick stop.
— If the brake pedal has no effect on the
lathe, push the STOP button, and refer to Brake & Switch on Page 78 to make any required adjustments.
-28-
Page 31
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
PREPARATION
15. Move the spindle lever to the OFF (middle)
position. Remove the end gear cover from the left side of the headstock. This activates a safety switch that should prevent the spindle from starting while this cover is removed.
16. Stand away from all the exposed gears on
the side of the headstock, and attempt to start spindle rotation. The spindle should not start.
— If spindle rotation does start with the end
cover removed, the safety switch is not operating correctly. This safety feature must operate properly before continuing operation. Press the STOP button to turn the lathe OFF, disconnect it from power, and call Tech Support for help.
17. Push the STOP button in, move the spindle
lever to the OFF position, then replace the end gear cover.
18. Lift the chuck guard up—this will activate
the chuck guard safety switch. Reset the STOP button and attempt to start spindle rotation. The spindle should not start.
— If spindle rotation does start with the
chuck guard in the up position, the safety switch is not operating correctly. This safety feature must operate properly before continuing operation. Press the STOP button to turn the lathe OFF, disconnect it from power, and call Tech Support for help.
19. Re-start spindle rotation, use the cutting
fluid pump switch on the control panel to start the pump, then open the valve. Verify that the cutting fluid flows from the nozzle, then turn the pump OFF.
Congratulations! The test run is complete. Turn the lathe OFF and perform the following Spindle Break-In procedure.
After the first 16 hours of use, the V-belts will stretch and seat into the pulley grooves. The V-belts must be properly re-tensioned after this period to ensure proper power transmission and avoid reducing the life of the belts. Refer to the V-Belts subsection on Page 77 for detailed instructions.
-29-
Page 32
13" Heavy 13® Gearhead Lathe
PREPARATION
Spindle Break-In
Before subjecting the lathe to full loads, it is essential to complete the spindle break-in process as described below. This will ensure the best results and maximum life of the precision components inside the lathe.
The break-in procedure must be performed in succession with the Test Run procedure described in this manual, because many of the test run steps prepare the lathe controls for the break-in process.
Important: Do not perform the break-in procedure independently from the Test Run section—serious damage could occur to the lathe if the controls are set differently than instructed in that section.
For Machines Mfg. Since 5/11
4. Use the foot brake to stop spindle rotation,
then run the lathe at 200 RPM for 10 minutes with the gearbox range lever on the headstock in the L (low) position, and then run the lathe another 10 minutes with the lever in the H (high) position.
5. While the oil is still warm and any metal
particles are still suspended in the oil, change the headstock and gearbox oil (refer to Lubrication beginning on Page 66 for detailed instructions).
6. Check the V-belt tension, and if necessary,
re-tension them (refer to V-Belts on Page 77 for detailed instructions).
Congratulations! The spindle break-in is complete.
Do not leave the lathe unattended during the Spindle Break-In procedure. If your attention is needed elsewhere during this procedure, stop the lathe and restart the procedure later from the beginning.
To perform the spindle break-in:
1. Successfully complete the Test Run
procedure beginning on Page 26.
2. Using the spindle speed levers to set the
spindle speed, run the lathe for 10 minutes at each of the spindle speeds starting with the lowest speed.
Note: If necessary, refer to Setting Spindle
Speed on Page 50 for detailed instructions.
3. Use the foot brake to stop spindle rotation,
set the spindle speed at 2000 RPM, then use the spindle lever to reverse the spindle rotation and run the lathe for 10 minutes.
Recommended Adjustments
For your convenience, the adjustments listed below have been performed at the factory. However, because of the many variables involved with shipping, we recommend that you at least verify the following adjustments to ensure the best possible results from your new machine.
Step-by-step instructions for these adjustments can be found on the pages referenced below.
Factory adjustments that should be verified:
s 4AILSTOCKALIGNMENTPage 40).
s #OMPOUNDANDCROSSSLIDEBACKLASH
adjustment (Page 74).
s 'IBADJUSTMENTSPage 75).
-30-
Page 33
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
g
Operation Overview
The purpose of this overview is to provide the novice machine operator with a basic understanding of how the machine is used durin operation, so they can more easily understand the controls discussed later in this manual.
Note: Due to the generic nature of this overview, it is not intended to be an instructional guide for performing actual machine operations. To learn more about specific operations and machining techniques, seek training from people experienced with this type of machine, and do additional research outside of this manual by reading "how-to" books, trade magazines, or websites.
To reduce the risk of serious injury when using this machine, read and understand this entire manual before beginning any operations.
OPERATION
To complete a typical operation, the operator does the following:
1. Puts on safety glasses, rolls up sleeves,
removes jewelry, and secures any clothing, jewelry, or hair that could get entangled in moving parts.
2. Examines the workpiece to make sure it is
suitable for turning, then securely mounts the workpiece in one of the chucks or on the faceplate, and removes the chuck key from the chuck.
3. Mounts the tooling, aligns it with the
workpiece, then backs it away to establish a safe startup clearance.
4. Clears all setup tools from the lathe.
5. Checks for safe clearances by rotating
the workpiece by hand at least one full revolution.
6. Moves slides to where they will be used
during operation.
7. Sets the correct spindle speed for the
operation.
Loose hair, clothing, or jewelry could get caught in machinery and cause serious injury or death. Keep these items away from moving parts at all times to reduce this risk.
During operation, small metal chips may become airborne, leading to serious eye injury. Wear safety glasses to reduce this risk.
8. If using power feed, selects the proper feed
rate for the operation.
9. Turns the master power switch ON, resets
the STOP button, then presses the spindle motor ON button.
10. Uses the spindle lever to start spindle
rotation.
11. Uses the carriage handwheels or power
feed options to move the tooling into the workpiece for operations.
12. When finished cutting, moves the spindle
lever to the OFF position, presses the foot brake to completely stop the spindle, then removes the workpiece.
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Page 34
13" Heavy 13® Gearhead Lathe
OPERATION
For Machines Mfg. Since 5/11
Chuck & Faceplate Mounting
This lathe is equipped with a D1-type spindle nose. This type of spindle uses camlocks that are adjusted with a chuck key to securely mount a chuck or faceplate with repeatable precision and ease.
Never use spindle speeds faster than the chuck RPM rating or the safe limits of your workpiece. Excessive spindle speeds greatly increase the risk of the workpiece or chuck being thrown from the machine with deadly force!
This lathe ships with the 3-jaw chuck installed. This is a scroll-type chuck where all three jaws move in unison when the chuck key is used.
The included 4-jaw chuck features independent jaws, which are used for square or unevenly­shaped stock, and to mount work that needs to be adjusted to near zero total indicated runout.
If neither chuck can hold your workpiece, the cast iron faceplate has slots for T-bolts that hold standard or custom clamping hardware. With the correct clamping hardware, a faceplate offers a wide range of uses, including machining non­concentric workpieces, straight turning between centers, off-center turning, and boring.
Installation & Removal Devices
Because chucks are heavy and often awkward to hold, some kind of lifting, support, or protective device should be used during installation or removal. The weight and size of the chuck will determine the appropriate device to use (refer to the following figure for examples).
A dropped chuck can cause amputation, serious crushing injuries, or property damage. Always use a lifting, support, or protective device to reduce this risk when installing or removing a chuck.
SMALL, LIGHTWEIGHT CHUCKS
Plywood Protection Plate for Chucks Installed by Hand
MEDIUM-SIZE, HEAVY CHUCKS
Plywood & 2x4 Chuck Cradle
Plywood Chuck Cradle (Straight Cuts)
Solid Block Chuck Cradle
Way Slot
Jaw Slot
Plywood Chuck Cradle (Curved Cuts)
-32-
LARGE, VERY HEAVY CHUCKS
Pre-Threaded Hole for Lifting Eye
Figure 28. Examples of common devices used during
chuck installation and removal.
Fabricated Steel Lifting Hook
Page 35
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
Chuck Installation
To ensure accurate work, it is extremely important to make sure the spindle nose and chuck mating surfaces/tapers are clean. Even a small amount of lint or debris can affect accuracy.
The chuck is properly installed when all camlocks are tight, the spindle and chuck tapers firmly lock together, and the back of chuck is firmly seated against the face of the spindle all the way around—without any gaps.
OPERATION
5. Incrementally tighten the camlocks in a
criss-cross or star pattern to ensure that the chuck seats evenly against the spindle.
6. When the chuck is fully seated and all the
camlocks are tight, verify that the cam line is between the two "V" marks on the spindle nose, as shown in the following figure.
To install the chuck:
1. DISCONNECT LATHE FROM POWER!
2. Use an appropriate lifting, support, or
protective device to protect the ways and support the chuck during the installation process.
3. Clean and lightly oil the camlock studs, then
thoroughly clean the mating surfaces of the spindle and chuck.
4. Install the chuck by inserting the camlock
studs straight into the spindle cam holes.
Important: Avoid inserting the studs by
pivoting them in from an angle or rotating the spindle. This can damage studs or spindle cam holes.
INCORRECTCORRECT
Cam line between “V”s
Figure 30. Cam line positioned between the "V" marks
after the camlocks are fully tightened.
— If the cam line is NOT between the "V"
marks when the camlock is tight, the stud may be installed at the incorrect height. To fix this, adjust the stud height as shown in the following figure. Make sure to re-install the stud cap screw afterward.
— If adjusting the stud height does not
correct the problem, try swapping stud positions on the chuck.
INCORRECT INCORRECT
Figure 29. Inserting camlock studs into spindle cam
holes.
Stud Too High:
Turn In
One-Turn
Figure 31. Correcting an improperly installed stud.
Stud Too Low:
Turn Out One-Turn
-33-
Page 36
13" Heavy 13® Gearhead Lathe
7. Verify that the chuck fits the spindle
properly by checking for any gaps between the mating surfaces.
— If there are no gaps, proceed to Step 8.
OPERATION
Chuck Removal
To remove the chuck:
1. DISCONNECT LATHE FROM POWER!
For Machines Mfg. Since 5/11
— If there is a gap, remove the chuck, re-
clean the mating surfaces carefully, and re-install. If the problem persists, contact our Tech Support.
8. Verify that the chuck/spindle tapers
are seated firmly together by removing the chuck, per the Chuck Removal instructions, and pay close attention to how easily the tapers release.
— If it was necessary to bump the chuck or
use a mallet to release the tapers, then they are seating together properly.
— If the tapers released easily with little
intervention, they are not seated together firmly as required. Remove the chuck, re­clean the mating surfaces carefully, and re-install. If the problem persists, contact our Tech Support.
Registration Marks
Lightly stamp registration marks across the mating seams of chuck components. These marks will help you re-install the chuck in the same position after removal, which ensures consistent chuck balance and turning results, and allows the same camlocks and studs to operate together for consistent locking and unlocking.
Camlock Spindle
Spindle & Chuck
Registration Marks
Chuck Halves
2. Use an appropriate lifting, support, or
protective device to protect the ways and support the chuck (refer to Installation & Removal Devices on Page 32).
3. Loosen the camlocks by turning the key
counterclockwise until each of the cam lines are aligned with its corresponding spindle mark (see Figure 33).
Cam line aligned with spindle mark
Figure 33. Camlock is fully loosened when the cam
line is aligned with the spindle mark.
Tip: Camlocks can become very tight. A cheater
pipe may be used as a last resort to add leverage when loosening. After loosening, you may need to wiggle the chuck key in the camlock to fully disengage the stud.
4. Using a dead blow hammer or other
soft mallet, lightly tap around the outer circumference of the chuck body to loosen it from the spindle.
5. Remove the chuck from the spindle, using
a light rocking motion to carefully slide the studs out of the cam holes.
for Chuck
Reassembly
-34-
Marks
Direct Mount
Camlock Chuck
Figure 32. Registration mark locations.
2-Piece
— If the chuck does not immediately come
off, rotate it approximately 60° and tap it again. Make sure all the marks on the cams and spindle are in proper alignment for removal.
Page 37
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
OPERATION
Scroll Chuck Clamping
This scroll-type chuck has an internal scroll-gear that moves all jaws in unison when adjusted with the chuck key. This chuck will hold cylindrical parts on-center with the axis of spindle rotation and can be rotated at high speeds if the workpiece is properly clamped and balanced.
Never mix jaw types or positions to accommodate an odd-shaped workpiece.
The chuck will spin out of balance and may throw the workpiece! Instead, use an independent jaw chuck or a faceplate.
Safer
Safer
Inside
UseJaw
Outside
UseJaw
Bar Stock
Unsafe Jaw Position and Poor Scroll Gear Engagement
Shallow
Bar Stock
Insufficient Jaw Clamping
Unstable Workpiece
Poor
Grip
Unstable Workpiece
4-Jaw Chuck
Refer to the Chuck Installation (see Page 33) and Chuck Removal (see Page 34) instructions to install or remove the 4-jaw chuck.
The 4-jaw chuck features independently adjustable hardened steel jaws for holding non­concentric or off-center workpieces. Each jaw can be independently removed from the chuck body and reversed for a wide range of work holding versatility.
Because of the dynamic forces involved in machining a non-concentric or off-center workpiece, always use a low spindle speed to reduce risk of the workpiece coming loose and being thrown from the lathe, which could cause death or serious personal injury.
Mounting Workpiece
1. DISCONNECT LATHE FROM POWER!
2. Place a chuck cradle or plywood on the
bedway below the chuck to protect the bedway surfaces.
Safer
Outside
UseJaw
Shallow
Bar Stock
Unsafe Jaw Position and Poor Scroll Gear Engagement
Inside
Safer
UseJaw
Figure 34. Jaw selection and workpiece holding.
Unsafe Jaw Position
Cylinder
Poor Scroll Gear Engagement
InsideUnsafe
UseJaw
3. Use the chuck key to open each jaw so the
workpiece will lay flat against the chuck face, jaw steps, or into the spindle opening.
4. With help from another person or a holding
device, position the workpiece so it is centered in the chuck.
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Page 38
13" Heavy 13® Gearhead Lathe
5. Tighten each jaw in small increments.
After you have adjusted the first jaw, continue tightening the remaining jaws in an opposing sequence, as shown by the sequential order in Figure 35.
1
3
OPERATION
Workpiece
Center Point
For Machines Mfg. Since 5/11
Faceplate
Refer to the Chuck Installation (see Page 33) and Chuck Removal (see Page 34) instructions to install or remove the faceplate.
The faceplate included with your lathe can be used for a wide range of operations, including machining non-concentric workpieces, straight turning between centers, off-center turning, and boring.
The tools needed for mounting a workpiece will vary depending on the type of setup you have.
4
Figure 35. 4-jaw tightening sequence.
6. After the workpiece is held in place by the
jaws, use a dial indicator to make sure the workpiece is centered in the chuck.
— If the workpiece is not correctly centered,
make fine adjustments by slightly loosening one jaw and tightening the opposing jaw until the workpiece is correctly positioned (see Figure 36 for an example).
2
Machining non-concentric workpieces at a high speed could cause the workpiece to be thrown from the spindle with deadly force at the operator or bystanders. To reduce this risk, only machine non-concentric workpieces at low speeds and clamp counter-weights to the faceplate to balance it.
Failure to properly secure a workpiece to the faceplate could cause the workpiece to be thrown from the lathe with deadly force at the operator or bystanders. Use a minimum of THREE independent clamping devices to hold the workpiece onto the faceplate.
Figure 36. Example photo of non-cylindrical workpiece
correctly mounted on the 4-jaw chuck.
-36-
Page 39
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
OPERATION
To mount a non-concentric workpiece to the faceplate:
1. DISCONNECT LATHE FROM POWER!
2. Protect the bedway with a piece of plywood.
3. With help from another person or a holding
device to support the workpiece, position it onto the faceplate and clamp it in place with a minimum of three independent clamping devices (see Figure 37 for an example).
Be sure to take into account the rotational
and cutting forces that will be applied to the workpiece when clamping it to the faceplate. If necessary, use counter-weights to balance the assembly and use a dial indicator to make sure that the workpiece is properly positioned for your operation.
Non-Cylindrical
Workpiece
Quill Lock
Lever
Quill
Handwheel
Figure 38. Tailstock and quill lock levers in locked
position.
Graduated Dial
Increments .....................................................0.001"
One Full Revolution ......................................0.100"
Increments on Quill
Inch ................................ 0"-4
Metric ..................... 0–110mm in 1mm Increments
3
Tailstock Lock
Lever
⁄8" in 1⁄16" Increments
Clamp
Faceplate
Figure 37. Example photo of workpiece clamped in a
faceplate.
Tailstock
The tailstock (see Figure 38) is typically used to support long workpieces by means of a live or dead center (refer to Centers on Page 41). It can also be used to hold a drill or chuck to bore holes in the center of a part. Custom arbors and tapers can also be cut on your lathe by using the offset tailstock adjustment.
Positioning Tailstock
1. Pull the tailstock lock lever backward (away
from the spindle) to unlock the tailstock from the bedway.
2. Slide the tailstock to the desired position.
3. Push the tailstock lock lever forward (toward
the spindle) to lock the tailstock against the bedway.
Using Quill
1. Move the quill lock lever toward the spindle
to unlock the quill.
2. Turn the quill handwheel clockwise to
move the quill toward the spindle or counterclockwise to move it away from it.
3. Move the lock lever away from the spindle to
secure the quill in place.
-37-
Page 40
13" Heavy 13® Gearhead Lathe
OPERATION
For Machines Mfg. Since 5/11
Installing Tooling
This tailstock uses a quill with an MT#5 taper that has a lock slot in the back of the bore that accepts tang arbors and drill bits (see Figures 39–40 for examples).
Screw
Solid
Open
Solid
End
Figure 39. Types of tapered arbors and tooling.
End
End
End
Tang
However, other tooling without tangs, such as the four remaining tools shown in Figure 39, can still be used if the potential load will not exceed the strength of the tapered fit. For example, this includes smaller drill chucks, drill bits, and centers.
Note: If the tooling has an open hole in the end but is too short to be exposed in the drift slot for removal, then a screw can be threaded into the end of the tool to provide a solid surface for the quill pin to push against when the quill is retracted for tool removal. Otherwise, removal of such tooling may be difficult.
To install tooling in the tailstock:
1. With the tailstock locked in place, unlock the
quill, then use the handwheel to extend it approximately 1".
2. Thoroughly clean and dry the tapered
mating surfaces of the quill and the center, making sure that no lint or oil remains on the tapers.
Tang
Figure 40. Example photos of inserting MT#5 tools
with tangs into the tailstock.
Note: If the tapered tool shaft has a tang, align
it with the slot in the back of the quill before seating it.
3. With a firm and quick motion, insert the
tool into the quill. Check to see if it is firmly seated by attempting to twist it—a firmly seated tool will not twist.
4. Unlock the tailstock and move it until the tip
of the tool is close to, but not touching, the workpiece, then re-lock the tailstock.
5. Start spindle rotation, unlock the quill, then
turn the quill handwheel clockwise to feed the tool into the workpiece.
-38-
Page 41
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
OPERATION
Removing Tooling
1. Use a shop rag to hold the tool.
2. Rotate the quill handwheel counterclockwise
until the tool is forced out of the quill.
— If the tool does not come loose by
retracting the quill, extend the quill and use a drift key in the slot shown in Figure 41 to remove the tool.
Drift Key Slot
Figure 41. Drift key slot in the side of the quill.
To offset the tailstock:
1. Loosen the hex bolts underneath both ends
of the tailstock to release the clamping pressure between the top and bottom castings (see Figure 42).
Adjustment
Set Screw
(1 of 2)
Offset
Indicator
Figure 42. Tailstock offset controls.
2. Rotate the adjustment set screws in opposite
directions for the desired offset (see the illustration in Figure 43).
Hex Bolt
(1 of 2)
Offsetting Tailstock
The tailstock can be offset from the spindle centerline for turning tapers. Move the tailstock top casting toward the front of the lathe to machine a taper at the tailstock end. Conversely, position the tailstock top casting toward the back of the lathe to machine a taper at the spindle end.
Note: The marks on the offset indicator are arbitrary. For a precise offset, use a dial indicator to check quill movement while adjusting the screws.
Tools Needed Qty
Hex Wrench 6mm .................................................1
Wrench 17mm .......................................................1
Turn CCW
Figure 43. Set screw adjustment in relation to
3. Retighten the clamping hex bolts underneath
the tailstock to secure the offset.
Turn CW
tailstock movement.
Turn CW
Turn CCW
-39-
Page 42
13" Heavy 13® Gearhead Lathe
OPERATION
For Machines Mfg. Since 5/11
Aligning Tailstock to Spindle Centerline
This is an essential adjustment that should be verified or performed each time the tailstock is used to turn concentric workpieces between centers or immediately after offsetting the tailstock when turning a taper. If the tailstock is not aligned with the spindle centerline when it is supposed to be, turning results will be inaccurate along the length of the workpiece.
Items Needed Qty
Hex Wrench 6mm .................................................1
Wrench 17mm .......................................................1
Round Stock 2" x 6" ...............................................2
Precision Level ......................................................1
To align the tailstock to the spindle centerline:
1. Use the precision level to make sure the
bedway is level from side-to-side and from front-to-back.
Note: As long as this dead center remains in the
chuck, the point of the center will remain true to the spindle centerline. The point will have to be refinished whenever the center is removed and then returned to the chuck.
4. Install a center in the tailstock.
5. Attach a lathe dog to the test stock from
Step 2, then mount it between the centers (see Figure 45 for an example).
— If the bedway is not level, correct
this condition before continuing with this procedure (refer to Leveling & Mounting on Page 23).
2. Center drill both ends of one piece of round
stock, then set it aside for use in Step 5.
3. Use the other piece of round stock to make
a dead center, and turn it to a 60° point, as illustrated in Figure 44.
Figure 45. Example photo of stock mounted between
the centers.
6. Turn 0.010" off the stock diameter.
7. Mount a test or dial indicator so that the
plunger is on the tailstock quill.
-40-
Figure 44. Turning a dead center.
Page 43
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
Note: If necessary in the following step, refer
to Offsetting Tailstock on Page 39 for detailed instructions.
8. Use calipers to measure both ends of the
workpiece.
OPERATION
Centers
Figure 48 shows the MT#5 dead centers included with the lathe. In addition, an MT#7– MT#5 tapered spindle sleeve is included for mounting centers in the spindle.
— If the test stock is thicker at the tailstock
end, move the tailstock toward the front of the lathe taper (see Figure 46).
Figure 46. Adjust tailstock toward the operator.
— If the test stock is thinner at the tailstock
end, move the tailstock toward the back of the lathe taper (see Figure 47).
1
⁄2 the distance of the amount of
Move the tailstock toward
the front of the lathe ½ the
distance of the taper.
Looking down from above.
1
⁄2 the distance of the amount of
Dead
Center
Carbide Tipped
Dead Center
Adapter
Sleeve
Figure 48. Adapter sleeve and dead centers.
Dead Centers
A dead center is a one-piece center that does not rotate with the workpiece and is used to support long, slender workpieces
Use the dead center in the spindle for operations where the workpiece rotates with the center and does not generate friction.
Looking down from above.
Move tailstock toward the
back of the lathe ½ the
distance of the taper.
Figure 47. Adjust tailstock away from the operator.
9. Repeat Steps 6–8 until the desired accuracy
is achieved.
The carbide-tipped dead center can better withstand the effects of friction and is best used in the tailstock where the workpiece will rotate against it. The tip of the center must be generously lubricated during the operation to avoid premature wear and maximize smooth operation. Using low spindle speeds will also reduce the heat and wear from friction.
-41-
Page 44
13" Heavy 13® Gearhead Lathe
OPERATION
For Machines Mfg. Since 5/11
Live Centers
A live center has bearings that allow the center tip and the workpiece to rotate together; it can be installed in the spindle and the tailstock quill for higher speeds. However, a live center typically does not provide the same level of rigidity as a dead center, and final workpiece accuracy can suffer as a result.
Mounting Dead Center in Spindle
1. DISCONNECT LATHE FROM POWER!
2. Thoroughly clean and dry the tapered
mating surfaces of the spindle bore, adapter sleeve, and the center, making sure that no lint or oil remains on the tapers.
Note: This will prevent the tapered surfaces from
seizing due to operational pressures, which could make it very difficult to remove the center.
Removing Center from Spindle
To remove the sleeve and center from the spindle, insert a piece of round bar stock or similar tool through the outboard end (on the left side of the headstock). Have another person hold onto the sleeve and center with a gloved hand or shop rag, then tap the sleeve loose.
To avoid premature wear of the dead center or damage to the workpiece, use low spindle speeds and keep the tip of the dead center mounted in the tailstock well lubricated.
Mounting Center in Tailstock
Either a carbide-tipped dead center or live center can be used in the tailstock. Mounting instructions are the same for both. Figure 50 shows an example photo of a dead center mounted in a tailstock.
3. Mount a chuck or faceplate onto the spindle,
whichever is correct for your operation.
4. Insert the center into the sleeve, then insert
the sleeve into the spindle bore through the chuck or faceplate.
Figure 49 shows an example photo of a
dead center installed in the spindle, using a lathe dog and faceplate for turning between centers.
Dead Center
Lathe
Dog
Carbide-Tipped
Dead Center
Figure 50. Example photo of using a carbide-tipped
dead center installed in the tailstock.
To mount a center in the tailstock:
1. DISCONNECT LATHE FROM POWER!
2. Thoroughly clean and dry the tapered
mating surfaces of the tailstock quill bore and the center, making sure that no lint or oil remains on the tapers.
Figure 49. Example photo of using a dead center with
a faceplate and lathe dog.
-42-
Page 45
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
OPERATION
3. Use the quill handwheel to feed the quill out
from the casting approximately 1".
Note: Do not extend the quill more than 2" or
stability and accuracy will be reduced.
4. Insert the center into the tailstock quill.
5. Seat the center firmly into the quill during
workpiece installation by rotating the quill handwheel clockwise to apply pressure, with the center engaged in the center hole in the workpiece.
Note: Only apply enough pressure with
the tailstock quill to securely mount the workpiece between centers. Avoid overtightening the center against the workpiece, or it may become difficult to remove later, and it will result in excessive friction and heat, which may damage the workpiece and center.
Mounting Workpiece Between Centers
1. DISCONNECT LATHE FROM POWER!
2. Drill center holes in both ends of the
workpiece.
3. Install a dead center in the spindle with
a lathe dog and a chuck or faceplate, then install a live center or carbide-tipped dead center in the tailstock.
4. Lubricate the workpiece center holes, then
mount the workpiece between the centers and hold it in place with light pressure from the tailstock center.
5. Seat the center firmly into the quill by
rotating the quill handwheel clockwise to apply pressure against the workpiece (see the example in Figure 52).
Removing Center from Tailstock
To remove the center from the quill, hold onto it with a gloved hand or shop rag, then rotate the quill handwheel counterclockwise to draw the quill back into the casting until the center releases.
If the center does not come loose by retracting the quill, extend the quill to expose the slot shown in Figure 51, then use a drift key to remove the center.
Drift Key Slot
Only apply enough pressure to securely
mount the workpiece between centers. Avoid over-tightening the center against the workpiece, or it may become difficult to remove later. Also, over-tightening will result in excessive friction and heat, which may damage the workpiece or center.
Figure 52. Example photo of a workpiece mounted
between the centers.
Figure 51. Drift key slot in the side of the quill.
-43-
Page 46
13" Heavy 13® Gearhead Lathe
!
OPERATION
Steady Rest
The steady rest supports long shafts and can be mounted anywhere along the length of the bedway.
Familiarize yourself with the steady rest components shown in Figure 53 to better understand its operation.
Finger
Adjustment
Knob
Leaf
Screw
For Machines Mfg. Since 5/11
4. Loosen the clamp knob that secures the two
halves of the steady rest and open the top portion, as shown in Figure 54.
Finger
Roller
Clamp
Knob
Figure 53. Steady rest components.
To install and use the steady rest:
1. DISCONNECT LATHE FROM POWER!
2. Thoroughly clean all mating surfaces, then
place the steady rest base on the bedways so the triangular notch fits over the bedway prism.
3. Position the steady rest where required to
properly support the workpiece, then tighten the hex nut shown in Figure 53 to secure it in place.
Hex Nut
Figure 54. Workpiece mounted in the steady rest.
5. Loosen the three leaf screws so the finger
roller positions can be adjusted.
6. Use the finger adjustment knobs to position
the bottom two finger rollers against the workpiece, as shown in the example of Figure 54.
7. Close the steady rest, then use the finger
adjustment knobs to adjust all three finger rollers so that they just touch the workpiece without causing deflection.
Note: The finger rollers should properly support
the workpiece along the spindle centerline while still allowing it to freely rotate.
8. Tighten the three leaf screws to secure the
settings.
-44-
Page 47
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
OPERATION
Follow Rest
The follow rest mounts to the saddle with two cap screws (see Figure 55). It is used on long, slender parts to prevent workpiece deflection from the pressure of the cutting tool during operation. Adjust the follow rest fingers in the same manner as the those on the steady rest.
Note: To reduce the effects of friction, lubricate the brass finger tips with generous lubricant during operation.
Cap
Screws
Carriage & Slide Locks
The carriage, cross slide, and compound rest have locks that can be tightened to provide additional rigidity during operation, especially during heavy cuts or close tolerance work.
See Figures 56–57 to identify the locations of the locks for each device.
Cross Slide
Lock
Carriage
Lock
Figure 55% Follow rest attachment.
Figure 56. Location of carriage and cross slide locks.
Compound Rest
Lock
Figure 57. Location of compound rest lock.
-45-
Page 48
13" Heavy 13® Gearhead Lathe
OPERATION
For Machines Mfg. Since 5/11
Compound Rest
The compound rest handwheel has an indirect­read graduated scale. This means that the distance shown on the scale represents the actual distance the cutting tool moves. The base of the compound rest has another graduated scale used for setting the cutting tool to a specific angle.
Graduated Dial
Increments ....................................0.001" (0.02mm)
One Full Revolution .....................0.100" (2.54mm)
Tool Needed Qty
Wrench 14mm .......................................................1
To set the compound rest at a certain angle:
1. Loosen the two hex nuts at the base of the
compound rest (1 of 2 shown in Figure 58).
Hex Nut
(1 of 2)
Compound
Rest
Four-Way Tool Post
The four-way tool post is mounted on top of the compound rest and allows a maximum of four tools to be loaded simultaneously.
Each tool can be quickly indexed to the workpiece by loosening the top handle, rotating the tool post to the desired position, then re-tightening the handle to lock the tool into position.
Installing Tool
Tool Needed Qty
Tool Post T-Wrench ............................................... 1
To install a tool in the tool post:
1. Adjust the tool post bolts so that the
cutting tool can fit underneath them (see Figure 59).
Tool Post
Bolt
Cutting
Tool
Angle Scale
Figure 58. Compound rest.
2. Rotate the rest to the desired angle, as
indicated by the scale at the base, then retighten the two hex nuts.
Tip: The first time you set the angle of the
compound rest for cutting threads, mark the location on the cross slide as a quick reference point. This will allow you to quickly return the compound rest to that exact angle the next time you need to cut threads.
Figure 59. Example of tool mounted in tool post.
Over-extending a cutting tool from the post will increase the risk of tool chatter, breakage, or tool loosening during operation, which could cause metal pieces to be thrown at the operator or bystanders with great force. DO NOT extend a cutting tool more than
2.5 times the width of its cross-section (e.g, 2.5 x 0.5" = 1.25").
2. Firmly secure the cutting tool with at least
two tool post bolts.
3. Check and adjust the cutting tool to the
spindle centerline, as instructed in the next subsection.
-46-
Page 49
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
OPERATION
Aligning Cutting Tool with Spindle Centerline
For most operations, the cutting tool tip should be aligned with the spindle centerline, as illustrated in Figure 60.
Cutting
Tool
Figure 60. Cutting tool aligned with spindle centerline
(viewed from tailstock).
Spindle Center
Line
Tools Needed Qty
Tool Post T-Wrench ............................................... 1
Steel Shims ............................................ As Needed
Cutting Tool ........................................................... 1
Fine Ruler .............................................................. 1
Tailstock Center .................................................... 1
To align the cutting tool with the tailstock center:
1. Mount the cutting tool in the tool post, then
secure the post so the tool faces the tailstock.
2. Install a center in the tailstock, and position
the center tip near the cutting tool tip.
3. Lock the tailstock and quill in place.
4. Adjust the height of the cutting tool so
that the tool tip is aligned vertically and horizontally with the center tip, as shown in Figure 61.
There are a number of ways to check and align the cutting tool to the spindle centerline. If necessary, you can raise the cutting tool by placing steel shims underneath it. The shims should be as long and as wide as the cutting tool to properly support it.
Below are two common methods:
Align the tip of the cutting tool with a center
s
installed in the tailstock, as instructed on the next page. For this to work, the tailstock must be aligned to the spindle centerline (refer to Aligning Tailstock To Spindle Centerline on Page 40 for detailed instructions).
s -AKEAFACINGCUTONAPIECEOFROUNDBAR
stock. If the tool is above or below the spindle centerline, a nub will be left in the center of the workpiece. Adjust the height of the tool, then repeat the facing cut to check the adjustment. Repeat as necessary until the center of the workpiece face is smooth.
(Top View)
Tailstock
Center
Cutting
Tool
Cutting
Tool
Figure 61. Cutting tool tip aligned with tailstock
center.
Tailstock
Center
(Side View)
-47-
Page 50
13" Heavy 13® Gearhead Lathe
OPERATION
For Machines Mfg. Since 5/11
Adjustable Feed Stop
Use the adjustable feed stop collar (shown in Figure 62) to set the location where the carriage should disengage from power feed.
When the apron stop plate contacts the stop collar during an operation that uses the feed rod, the clutch disengages the carriage from the feed rod and movement stops.
Stop
Plate
Stop
Collar
Apron
Micrometer Stop
The micrometer stop allows you to stop the carriage at the same position for repeat cuts, such as when turning up to a shoulder. The micrometer stop includes a graduated dial that allows you to precisely position the stop.
The micrometer stop is only designed to be used when feeding the carriage by hand—it should not be used as a stop for power feed or threading operations, because this lathe is not equipped with an automatic feed clutch.
The carriage stop on this lathe will NOT automatically stop the carriage during power feed or threading operations when the carriage is engaged with the leadscrew! Failure to heed this notice could result in the carriage crashing and causing severe machine or property damage.
Figure 62. Adjustable feed rod stop collar.
The adjustable feed stop system is designed to stop longitudinal carriage movement at the desired location ONLY when the carriage is engaged with the feed rod.
When the carriage is engaged with the leadscrew for threading operations, the adjustable feed stop system WILL NOT stop carriage movement—you must use the half nut lever instead. Otherwise, the carriage can crash into the chuck, or if it contacts the stop, the leadscrew shear pin will break.
Before doing any threading operation, make sure to loosen the feed stop collar so it slides freely on the feed rod and will not interfere with carriage travel.
Tools Needed Qty
Hex Wrench 8mm .................................................1
To set the micrometer stop:
1. DISCONNECT LATHE FROM POWER!
2. Loosen the cap screws shown in Figure 63,
then use the carriage handwheel to position the carriage at the desired stopping point.
Cap Screws
Graduated
Dial
Figure 63. Micrometer stop.
3. Move the micrometer stop up to the carriage,
use the graduated dial to fine tune the position, then retighten the cap screws loosened in Step 2.
Stop Rod
-48-
4. Verify that tooling will not make contact
with the chuck, jaws, or other components.
Page 51
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
OPERATION
Manual Feed
The handwheels shown in Figure 64 allow the operator to manually move the cutting tool.
Cross Slide Handwheel
Carriage
Handwheel
Figure 64. Carriage Controls.
Carriage Handwheel
The carriage handwheel moves the carriage left or right along the bed. It has a graduated dial with 0.01" increments, and one full revolution moves the carriage 0.80". Pull the handwheel out to disengage it during power feed operations— this will prevent entanglement hazards.
Compound
Rest
Handwheel
Spindle Speed
Using the correct spindle speed is important for safe and satisfactory results, as well as maximizing tool life.
To set the spindle speed for your operation, you will need to: 1) Determine the best spindle speed for the cutting task, and 2) configure the lathe controls to produce the required spindle speed.
Determining Spindle Speed
Many variables affect the optimum spindle speed to use for any given operation, but the two most important are the recommended cutting speed for the workpiece material and the diameter of the workpiece, as noted in the formula shown in Figure 65.
*Recommended
Cutting Speed (FPM) x 12
Dia. of Cut (in inches) x 3.14
*Double if using carbide cutting tool
Figure 65. Spindle speed formula for lathes.
= SpindleSpeed (RPM)
Cross Slide Handwheel
The cross slide handwheel moves the tool toward and away from the work. Adjust the position of the graduated scale by holding the handwheel with one hand and turning the dial with the other. The cross slide handwheel has a direct­read graduated dial which means that the distance on the dial reflects the amount removed from the diameter of the workpiece. The dial has 0.001" (0.02mm) increments, and one full revolution moves the slide 0.100" (5.08mm). Rotate the dial collar 180° to read in metric units.
Compound Rest Handwheel
The compound rest handwheel moves the cutting tool linearly along the set angle of the compound rest. The compound rest angle is set by hand­rotating it and securing in place with two hex nuts. The compound rest has an indirect-read graduated dial with 0.001" (0.02mm) increments. One full revolution of the handwheel moves the slide 0.100" (2.54mm). Rotate the dial collar 180° to read in metric units.
Cutting speed, typically defined in feet per minute (FPM), is the speed at which the edge of a tool moves across the material surface.
A recommended cutting speed is an ideal speed for cutting a type of material in order to produce the desired finish and optimize tool life.
The books Machinery’s Handbook or Machine Shop Practice, and some internet sites, provide excellent recommendations for which cutting speeds to use when calculating the spindle speed. These sources also provide a wealth of additional information about the variables that affect cutting speed and they are a good educational resource.
Also, there are a large number of easy-to-use spindle speed calculators that can be found on the internet. These sources will help you take into account the applicable variables in order to determine the best spindle speed for the operation.
-49-
Page 52
13" Heavy 13® Gearhead Lathe
OPERATION
For Machines Mfg. Since 5/11
Setting Spindle Speed
Selecting one of the 8 spindle speeds available is a combination of configuring the spindle range lever and the spindle speed lever shown in Figure 66.
Speed
Lever
Spindle Range
Lever
Figure 66. Spindle speed controls.
The spindle speed and range levers control the gear configuration in the headstock to produce the selected spindle speed. Refer to the chart below for the available spindle speeds available.
Low Range (RPM) High Range (RPM)
80 488
127 772
200 1245
320 2000
Configuration Examples
Using the controls on the lathe, follow along with these two examples for setting the spindle speed to gain a better understanding of this task.
Setting Spindle Speed of 200 RPM
1. Make sure the spindle is completely stopped
and the spindle lever is in the OFF (middle) position.
2. Move the spindle range lever to the right
so that the arrow on top of its hub points toward the L (low) label (see the illustrated in Figure 67).
Note: If necessary, use the chuck key to rock
the spindle back-and-forth to help mesh the gears as you move the levers.
:>
$
"
'
"
&
$
#
)
$
#
$
)
)
$
"
"
"
%
$
"
&
*
*
"
*
Lever Set to 200 RPM
Figure 67. Setting the spindle speed to 200 RPM.
3. Move the spindle speed lever so that the 200 on its hub is also pointing at the L label.
Spindle Range
Lever Set to LOW
Spindle Speed
ALWAYS make sure the spindle is completely stopped BEFORE using the headstock control levers to make changes. If the spindle is rotating when attempting to change the spindle speed, the headstock gears will suffer damage!
Operating the lathe at spindle speeds higher than 350 RPM when the high (H) gearbox range is selected could result in gearbox damage. Always use spindle speeds of 350 RPM or lower when using the high (H) gearbox range.
-50-
Note: You will hear a distinctive click when the
spindle speed lever is in the correct position.
The lathe is now set for a spindle speed of 200 RPM.
Page 53
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
OPERATION
Setting Spindle Speed of 2000 RPM
1. Make sure the spindle is completely stopped
and the spindle lever is in the OFF (middle) position.
2. Move the spindle range lever to the right
so that the arrow on top of its hub points toward the H (high) label (see the illustrated in Figure 68).
Note: If necessary, use the chuck key to rock
the spindle back-and-forth to help mesh the gears as you move the levers.
:>
%
"
$
"
"
"
$
"
"
$
'
&
$
#
Figure 68. Setting the spindle speed to 2000 RPM.
&
*
*
*
"
)
)
)
$
$
#
3. Move the spindle speed lever so that the 2000 on its hub is also pointing at the H
label.
Spindle Range
Lever Set
to HIGH
Spindle Speed
Lever Set to
2000 RPM
Power Feed
Both the carriage and cross slide have power feed capability when the carriage is engaged with the feed rod. The rate that these components move (feed rate) is controlled by the headstock and quick-change gearbox lever positions, and the end gear configuration.
Feed rate and spindle speed must be considered together. Keep in mind that the feed rate is expressed in the amount of travel per revolution of the spindle. The sources you use to determine the optimum spindle speed for an operation will also provide the optimal feed rate to use with that spindle speed.
Often, the experienced machinist will use the feeds and speeds given in their reference charts or web calculators as a starting point, then make minor adjustments to the feed rate (and sometimes spindle speed) to achieve the best results.
The carriage can alternately be driven by the leadscrew for threading operations. However, this section only covers the use of the power feed option for the carriage and cross slide components for non-threading operations. To learn how to power the carriage for threading operations, refer to Threading on Page 56.
Note: You will hear a distinctive click when the
spindle speed lever is in the correct position.
The lathe is now set for a spindle speed of 2000 RPM.
Operating the lathe at spindle speeds higher than 350 RPM when the high (H) gearbox range is selected could result in gearbox damage. Always use spindle speeds of 350 RPM or lower when using the high (H) gearbox range.
-51-
Page 54
13" Heavy 13® Gearhead Lathe
ALWAYS make sure the spindle is completely stopped BEFORE using the headstock control levers to make changes. If the spindle is rotating when attempting to change the configuration of the headstock feed controls, the gears in the headstock and quick-change gearbox will become damaged!
OPERATION
For Machines Mfg. Since 5/11
A. Feed Range Lever: Selects the low or high
feed rate range by re-aligning the headstock transfer gear. In the middle position, disables power feed.
B. Feed Direction Lever: When the lathe is
stopped, selects the direction for power feed.
Note: When the lathe is running, use the quick-
change feed direction knob on the apron.
Power Feed Controls
Use Figures 69–70 and the following descriptions to become familiar with the locations and functions of the controls that you will use to set up the correct power feed for your operation.
Note: Before using power feed, you may have to re-configure the end gears, depending on how they are set up. Refer to End Gears on Page 54 for detailed instructions.
A
C
B
C. Feed Rate Chart: Displays the settings for
the headstock and quick-change gearbox controls for the selected feed rate. Refer to Setting Feed Rate subsection on the next page for detailed instructions.
D. Quick-change Gearbox Feed Levers:
Configure the quick-change gearbox gears for the feed rate selected.
— Left Lever Positions: A–C
— Middle Lever Positions: R–T
— Right Lever Positions: V–Z
— Bottom Lever Positions: 1–8
Even though there is a lock-out device in the apron to prevent the feed selection lever and the half nut lever from being engaged at the same time, this lock-out device could break if forced. Attempting to engage these levers at the same time could cause severe lathe damage and will void the warranty.
D
Figure 69. Power feed controls on the headstock.
-52-
Page 55
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
OPERATION
Setting Power Feed Rate
The feed rate chart on the upper right of the headstock face displays the settings for the headstock feed controls for metric and inch feed rates.
E
F
Figure 70. Apron power feed controls.
E. Feed Selection Lever: Directs the power feed
to either the cross slide or the carriage.
When the lever is down and the indent pin
is pointing up, the cross slide is selected. Conversely, when the lever is up and the pin is pointing down, the carriage is selected.
In the middle position, the apron gears are
disengaged from the feed rod and neither component will move.
Note: When using this lever, you may need
to slightly rotate the handwheel of the component you are trying to engage, so that the apron gears can mesh.
F. Apron Feed Direction Knob: Changes the
feed direction when the lathe is running.
The advantage of this knob is that you can
quickly reverse power feed direction while the spindle is rotating—without having to turn the lathe off, waiting until the spindle is stopped, then using the feed direction lever on the headstock.
Depending on the combined configuration of the headstock feed direction lever and the apron feed direction knob, the actual direction of power feed may be different from the printed indicators on the machine!
Using the controls on the lathe, follow along with the example below to better understand how to set the lathe for the desired power feed rate.
Setting Power Feed Rate of 0.18mm/rev
1. Make sure the end gears are in the standard
configuration, which is applicable for general feed operations (refer to End Gears on the next page for detailed instructions).
2. Locate the line in the feed rate chart that
lists the setting for 0.18mm of feed per revolution of the spindle, as illustrated in Figure 71.
mm
.050 LCT1W .002
.055 LCT2W .0022 .065 LCT4W .003 .085 LCT8W .0033
.10 LCS2W .004 .13 LCS4W .005 .18 LCS8W .007
Figure 71. Feed rate chart.
When using power feed to move the cross slide, the feed rate is the feed rate chart.
3. The configuration string of characters to
the right of the selected feed rate (LCS8W) displays the positions to set the feed controls for a feed rate of 0.18mm/rev. (see Figure
71).
1
in.
⁄2 the value stated in
-53-
Page 56
13" Heavy 13® Gearhead Lathe
Note: In the next step, use the chuck key to rock
the spindle back and forth to help mesh the gears as you make adjustments.
4. Position the controls as directed by the configuration string as follows (see Figure 72):
OPERATION
For Machines Mfg. Since 5/11
End Gears
The end gears can be setup for the standard or alternate configuration, depending upon the type of operation to be performed. The lathe is shipped with the end gears in the standard configuration.
L Move the feed range lever to the low (Low)
position.
C Point the left quick-change gearbox lever
to the C.
S Move the middle quick-change gearbox
lever to the S.
8 Position the bottom gearbox lever in the 8
slot.
W Point the right gearbox lever to the W.
Standard End Gear Configuration
Use the standard end gear configuration for inch threading, metric threading, and all general feed operations.
In this configuration, the end gears are installed as follows: the 24T end gear is installed in the top position, the 44T/56T transposing gears in the middle position, and the 57T end gear in the bottom position, as shown in Figure 73. In this configuration the 56T and 57T gears are meshed.
44T
24T
56T
.18 LCS8W .007
Figure 72. Power feed controls positioned for
0.18 mm/rev.
The lathe is now set up for a power feed rate of
0.18mm per spindle revolution.
-54-
57T
24T
56T
44T
Inch and Metric Pitch
Threading
57T
Figure 73. End gears in the standard configuration.
Inch and Metric Feeding
Page 57
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
OPERATION
Alternate Configuration
The alternate end gear configuration is used when cutting modular or diametral threads. The 57T end gear is positioned on the outside so that it meshes with the 44T transposing gear instead of the 56T gear, as illustrated in Figure 74.
24T
56T
44T
Modular and Diametral
Pitch Turning
57T
Figure 74. Alternate end gear configuration.
4. Loosen the pivot arm hex nut shown in
Figure 75, then swing the pivot arm to the left so that 44T/56T gears are away from the 57T gear. Hand tighten the hex nut to keep the arm in place.
5. Use a stiff brush and mineral spirits to clean
away the debris and grime from the gears and shafts, then lubricate these devices as instructed in the End Gears lubrication subsection on Page 70.
6. Making sure to keep the key seated in the
shaft, remove the spacer and the 57T gear, then re-install them as follows:
— For the standard end gear configuration,
slide the 57T gear on first, then the spacer on the outside.
— For the alternate end gear configuration,
slide the spacer on first, then the gear.
Configuring End Gears
Tools Needed Qty
Hex Wrench 6mm .................................................1
Wrench 22mm .......................................................1
To configure the end gears:
1. DISCONNECT LATHE FROM POWER!
2. Remove the headstock end gear cover.
3. Remove the cap screw, lock washer, and flat
washer from the bottom 57T end gear (see Figure 75).
Pivot
Hex Nut
7. Re-install the cap screw, lock washer, and
flat washer you removed in Step 3 to secure the spacer and 57T gear.
Note: DO NOT overtighten the cap screw—
it merely holds the gear in place. Overtightening it will make it harder to remove later and may restrict the rotation of the gears.
8. Slide the pivot arm back so that either the
44T or the 56T meshes with the 57T gear, then retighten the pivot arm hex nut.
Note: Make sure to keep approximately 0.002"
play between the gears.
9. Replace and secure the end gear cover before
connecting the lathe to power.
Cap Screw,
Washers & Spacer
Figure 75. End gear components.
-55-
Page 58
13" Heavy 13® Gearhead Lathe
OPERATION
Threading
The following subsections describe how to use the threading controls and charts to set up the lathe for a threading operation. If you are unfamiliar with the process of cutting threads on a lathe, we strongly recommend that you read books, review industry trade magazines, or get formal training before attempting any threading projects.
Headstock Threading Controls
The threading charts on the headstock face display the settings for metric, inch, modular, and diametral threading.
Using the controls on the lathe, follow along with the example below to better understand how to set up the lathe for the desired threading operation.
Setting Metric Thread Pitch of 1.75
1. Make sure the end gears are in the standard
configuration, which is used for all metric threading (refer to End Gears on Page 54 for detailed instructions).
For Machines Mfg. Since 5/11
3. The configuration string of characters to the right of the selected thread pitch (LS8Y) displays the positions to set the threading controls for a metric thread pitch of 1.75 (see Figure 76).
4. Position the controls as follows:
Note: Each of the thread charts has a C or V
in the header that is to be used for all of the listings in that chart. For the C, use the left quick-change gearbox lever, and for the V use the right.
L Move the feed range lever to the low (Low)
position.
S Point the middle quick-change gearbox
lever to the S.
8 Position the bottom gearbox lever in the 8
slot.
Y Point the right gearbox lever to the Y.
The lathe is now set up to cut 1.75mm threads.
2. Locate the line in the metric thread chart
that lists the setting for 1.75 threads per millimeter, as illustrated in Figure 76.
mm
C
.2 LT1Z .225 LT2Z .25 LT3Z
.3 LT6Z .35 LT8Z .4 LS1Z
.45 LS2Z
Figure 76. Metric thread chart with 1.75mm
1.2 LR6Z
1.25 LS3Y
1.3 LR7Y
1.4 LR8Z
1.5 LS6Y
1.75 LS8Y
2.0 LR1Y
highlighted.
6.5 HS7Y 7 HS8Y 8 HR1Y
9 HR2Y 10 HR3Y 11 HR4Y
12 HR6Y
-56-
Page 59
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
OPERATION
Apron Threading Controls
The half nut lever engages the carriage with the leadscrew which moves the carriage and cutting tool, along the length of the workpiece for threading operations (see Figure 77).
Important: Make sure the feed selection lever is in the disengaged (middle) position before attempting to engage the half nut.
Feed Control
Lever
Half Nut
Lever
Thread Dial
The numbers on the thread dial are used with the thread dial chart to show when to engage the half nut during inch threading. The thread dial gear must be engaged with the leadscrew for this to work. Loosen the knurled knob on the thread dial, pivot the dial gear toward the leadscrew so that it properly meshes with the leadscrew threads, then re-tighten the knob, as shown Figure 78.
Leadscrew
Dial Gear
Knurled
Knob
Cross Slide
Disengaged
Carriage
Feed Control
Lever
Figure 77. Apron threading controls.
Disengaged
Engaged
Figure 78. Thread dial engaged with the leadscrew.
Halfnut
Lever
When threading, we recommend using the slowest speed possible and avoiding deep cuts, so you are able to disengage the half nut when required and prevent an apron crash!
-57-
Page 60
13" Heavy 13® Gearhead Lathe
OPERATION
For Machines Mfg. Since 5/11
Thread Dial Chart
Find the TPI (threads per inch) that you want to cut in the left column of the thread dial chart (see Figure 79), then reference the dial number to the right of it. The dial numbers indicate when to engage the half nut for a specific thread pitch. The thread dial chart can also be found on the front of the thread dial housing.
In.
4,8,12,16,20,24, 28,32,36,40,44, 48,56,60,72
2,6,10,14, 18,22,26, 30,54
3,5,7,9, 11,13,15, 19,23,27
2½,3½,4½, 7½,11½,13½
2¼,2¾, 3¼,3¾
7
⁄8
2
2
3
1
4
Any Position
Non­Numbered Position Numbered Position 1,2,3,4
Position 1,3 or 2,4
Position 1 Only
Same as Metric Threads
Even TPI Not Divisible By 4
For threading a TPI that is even but not divisible by 4, use any of the non-numbered lines on the thread dial (see Figure 81).
TPI
2,6,10,14, 18,22,26, 30,54
Non­Numbered Position
Figure 81. Marks are selected on the dial for threading
even TPI not divisible by 4.
Odd Numbered TPI
For odd numbered TPI, use any of the numbered lines on the thread dial (see Figure 82).
TPI
3,5,7,9, 11,13,15, 19,23,27
Numbered Position 1,2,3,4
Figure 79. Thread dial chart.
Note: The thread dial is not used for metric
threading, or diametral and modular pitches. You must leave the half nut engaged from the beginning until the turning is complete for these types of operations.
The following examples explain how to use the thread dial chart.
TPI Divisible By 4
For threading a TPI that is divisible by four, use any line on the thread dial (see Figure 80).
TPI
4,8,12,16,20,24,
Any Position 28,32,36,40,44, 48,56,60,72
Figure 82. Numbers are selected on the dial for
threading odd numbered TPI.
1
⁄2 Fractional TPI
Use any opposing number pairs—2/4 or 1/3 on the thread dial for
1
⁄2 fractional TPI (see Figure
83). For example, to cut a 31⁄2 thread, select 1 or 3 on the dial.
TPI
2½,3½,4½, 7½,11½,13½
Figure 83. Opposing number group are selected on
dial for cutting 1⁄2 thread TPI.
Position 1,3 or 2,4
Figure 80. Any position on the dial for threading TPI
divisible by 4.
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Page 61
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
1
⁄4 or 3⁄4 Fractional TPI
For TPI that have a
1
⁄4 or 3⁄4 fraction, use position
1 on the thread dial (see Figure 84).
OPERATION
Chip Drawer
The chip drawer catches swarf and metal chips during the machining process. It contains a screen that prevents large chips from returning
2¼,2¾, 3¼,3¾
TPI
Position 1 Only
to the reservoir with the run-off coolant and causing damage to the pump.
Also, it slides open and is removable for cleaning (see Figure 86).
Figure 84. Position for 1⁄4 or 3⁄4 fractional TPI.
7
2
⁄8 TPI
The thread dial is not used for 2
7
⁄8 or metric threading, or diametral and modular pitches (see Figure 85). The half nut must stay engaged with the leadscrew throughout the entire threading operation.
27⁄8
Same as Metric Threads
Figure 85. Half nut stays engaged for 2
Thread Dial
Not Used
7
⁄8 TPI.
Figure 86. Chip drawer.
The chip drawer is very heavy. Unless removing the chip drawer for cleaning, do not pull it out more than halfway; otherwise, it could fall out and cause a crushing injury. If removing the drawer for cleaning, get assistance!
-59-
Page 62
13" Heavy 13® Gearhead Lathe
Coolant System
OPERATION
For Machines Mfg. Since 5/11
When the coolant pump is turned ON, the fluid is delivered through the nozzle attached to the carriage. The flow is controlled by the valve lever at the base of the nozzle (see Figure 87).
Valve Lever
Coolant
Pump
Switch
Figure 87. Coolant flow controls.
Always use high quality coolant and follow the manufacturer's instructions for diluting. The quick reference table shown in Figure 88 can help you select the appropriate fluid.
BIOLOGICAL & POISON
HAZARD! Use the correct personal protection equipment when handling coolant. Follow federal, state, and fluid manufacturer requirements for proper disposal.
Running the pump without adequate fluid in the coolant tank may permanently damage it, which will not be covered under warranty.
To use the coolant system on your lathe:
1. Make sure the coolant tank is properly
serviced and filled with the appropriate fluid, and that you are wearing the necessary personal protection equipment.
2. Position the coolant nozzle for your
operation.
Refer to Coolant System Service on Page 71 for detailed instructions on how to add or change fluid. Check the coolant regularly and promptly change it when it becomes overly dirty or rancid, or as recommended by the fluid manufacturer.
Workpiece Dry
Aluminum
Brass
Bronze
Cast iron
Low Carbon Steel
Alloy Metals
Stainless Steel
General Note: Coolants are used for heavy-duty lathe operations and production turning. Oil-water emulsions and synthetic cutting fluids are the most common for typical lathe operations. Sulferized oils often are used for threading. For small projects, spot lubrications can be done with an oil can or brush, or omitted completely.
XXX
XXX X
X
Soluble Oil
3. Use the coolant pump switch on the control
panel to turn the pump ON.
4. Adjust the flow of coolant by using the valve
lever near the base of the nozzle hose.
Important: Promptly clean any splashed fluid
from the floor to avoid a slipping hazard.
Water
XX
XX
XXXX
XXXX
Synthetic
Coolants
Sulferized
Oil
Mineral
OIl
-60-
Figure 88. Coolant selection table.
Page 63
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
ACCESSORIES
Accessories
This section includes the most common accessories available for your lathe, which may be available through your local South Bend Lathe Co. dealer. If you do not have a dealer in your area, please call us at (360) 734-1540 or email us at cs@southbendlathe.com.
SB1279—10 Pc. Precision 5–C Collet Set
Set of 10 collets sized from as the individual collets, only packaged in one convenient set.
1
⁄8" - 3⁄4". Same quality
D1-5 Back Plates
1
SB1397—6 SB1399—8 SB1401—10
⁄4"
1
⁄4"
1
⁄2"
Sized to fit D1-5 chuck mounts, these back plates are precision made and mount to your chuck with minimal modifications.
Figure 91. D1-5 Back Plate.
Figure 89. Model SB1279 10 Pc. 5-C Collet Set.
SB1264—Collect Attachment
This collet attachment takes advantage of the South Bend factory-made collet port in the lathe gear cover. This accessory installs easily on these South Bend Lathes without having to modify the gear cover. The Model SB1264 is capable of delivering years of trouble-free service. It is manufactured with the same high-quality workmanship, materials, and tolerances South Bend machinery is known for.
SB1263—Taper Attachment
This taper attachment mounts quickly to the back bedway of your lathe. Accurate tapers of up to 12" can be produced without repositioning the attachment, having to offset the tailstock, or disengaging the cross slide nut. The Model SB1263 features scales at both ends, reading inches-per-foot and degrees. An angle adjusting knob with fine threads achieves exacting control when setting tapers.
Figure 90. Model SB1264 Collect Attachment.
Figure 92. Model SB1263 Taper Attachment.
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Page 64
13" Heavy 13® Gearhead Lathe
ACCESSORIES
For Machines Mfg. Since 5/11
Keyless Integral Chucks
1
SB1379—MT #3 SB1380—MT #3
⁄2"
5
⁄8"
These keyless chucks are produced with an integral shank to maximize concentricity between the body, shank, and jaws. They start as a one-piece high-alloy body which is turned, then finish ground throughout, making them as close to zero TIR (Total Indicated Runout) as can be. Keyless chuck self-tighten, so a spanner is provided to ease tool removal.
Figure 93. MT #3 Keyless Chuck.
SB1298—SBL Bench Lathe Shop Clock SB1299—SBL Toolroom Lathe Shop Clock SB1300—SBL Lathe with Man
These fine traditional shop clocks are constructed with a metal antique-finished frame. They are easy to read from a distance and measure 14" in diameter. Pictures just don't do them justice. They are very nice quality clocks and perfect for the South Bend Lathe aficionado.
SB1238—High Performance MT#3 Live Center
s 3HAFTSAREMADEOFALLOYSTEELANDVACUUM
heat-treated to HRC60°±1 for high rigidity and durability.
s #ENTERSUSEACOMBINATIONOFROLLERBEARINGS
thrust bearings, and ball bearings.
s 7ATERPROOFDESIGN
Figure 95. SB1238 High Performance Live Center.
SB1245—MT#2 Bull Nose Center
s #R-OSTEELHARDENEDTO(2#Ò s 4APERROLLERBALLBEARINGCONSTRUCTION s 'REATFORTURNINGPIPES
SB1298 SB1299
SB1300
Figure 94. Antique-finished South Bend shop clocks.
-62-
2.05" 3.39"
3.07"
0.59"
70°
Figure . SB1245 MT#2 Bull Nose Center.
6.14"
0.71"
Page 65
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
ACCESSORIES
SB1365—Way Oil
Engineered for the high pressure exerted on horizontal or vertical ways and slides. Protects against rust and corrosion. Ensures stick-free, smooth motion which maximizes finishes and extends the life of your machine Won't gum up! 12 oz. AMGA#2 (ISO 68 equivalent)
Figure 96. SB1365 Way Oil.
SB1251—Machinist's Oak Tool Box
Proudly made in the South Bend tradition, this heavy-duty oak tool chest will safeguard your finest tools for many years of dependable service. Solidly constructed with mortise and tenon joinery, this tool box features a locking top lid and front panel and 13 drawers of various sizes. Seven drawers even have removable dividers for organizing and protecting tools. All drawers and top compartment are felt-lined for added protection. The front panel secures all drawers when the top lid is latched or locked and neatly slides under the bottom drawer when accessing the drawers. All hardware is brass including the heavy-duty side handles. Weighs 65 lbs.
SB1282—High Performance MT#3 Live Center Set
South Bend brand live centers are the best centers in the industry made with pride and uncompromising quality.
s 3HAFTSAREMADEOFALLOYSTEELANDVACUUM
heat-treated to HRC60°±1 for high rigidity and durability.
s #ENTERSUSEACOMBINATIONOFROLLERBEARINGS
thrust bearings, and ball bearings.
s 7ATERPROOFDESIGN
Figure 98. SB1251 Machinist's Oak Tool Box.
Figure 97. High Performance Live Center Set.
-63-
Page 66
13" Heavy 13® Gearhead Lathe
MAINTENANCE
Maintenance Schedule
!
For optimum performance from this machine, this maintenance schedule must be strictly followed. We strongly recommend all operators make a habit of following the daily maintenance procedures. Use the chart provided on Page 65 to ensure this is done.
Ongoing
The condition of machine components should be carefully observed at all times to minimize the risk of injury or machine damage. If any of the conditions below are observed, stop the lathe immediately, disconnect power, and correct the condition before resuming operations:
s ,OOSEMOUNTINGBOLTSORFASTENERS s 7ORNFRAYEDCRACKEDORDAMAGEDWIRES s 'UARDSREMOVED s 34/0BUTTONNOTWORKINGCORRECTLYORNOT
requiring you to reset it before starting the machine again.
s !REDUCTIONINBRAKINGSPEEDOREFFICIENCY s /ILLEVELNOTVISIBLEINTHESIGHTGLASSES s #OOLANTNOTFLOWINGOUT s Damaged or malfunctioning components.
Daily, Before Operations
s #HECKADDHEADSTOCKOILPage 66). s #HECKADDGEARBOXOILPage 67). s #HECKADDAPRONOILPage 67). s #HECKADDCOOLANTPage 71). s ,UBRICATETHEWAYSPage 68). s !DDOILTOTHEBALLOILERSPage 69). s #LEANLUBRICATETHELEADSCREWPage 68). s $ISENGAGETHEFEEDSELECTIONLEVERONTHE
apron (to prevent crashes upon startup).
s %NSURECARRIAGELOCKBOLTISLOOSE
Always disconnect power to the machine before performing maintenance. Failure to do this may result in electrocution or accidental startup injury.
For Machines Mfg. Since 5/11
Daily, After Operations
s $EPRESS34/0BUTTONANDSHUTOFF the
master power switch (to prevent accidental startup).
s 6ACUUMCLEANALLCHIPSANDSWARFFROMBED
slides, and chip drawer.
s 7IPEDOWNALLUNPAINTEDORMACHINED
surfaces with an oiled rag.
Monthly
s $RAINANDCLEANTHECOOLANTTANKTHENADD
new fluid (Page 71).
Annually
s #HANGETHEHEADSTOCKOILPage 66). s #HANGETHEAPRONOILPage 67). s #HANGETHEGEARBOXOILPage 67). s ,UBRICATEENDGEARSPage 70). s #HECKLEVELBEDWAYPage 23).
Cleaning & Protecting
Regular cleaning is one of the most important steps in taking care of this lathe. We recommend that the cleaning routine be planned into the workflow schedule, so that adequate time is set aside to do the job right.
Typically, the easiest way to clean swarf from the bed ways and chip drawer is to use a wet/dry shop vacuum that is dedicated for this purpose. The small chips left over after vacuuming can be wiped up with a slightly oiled rag. Avoid using compressed air to blow off chips, as it may drive them deeper into moving surfaces and could cause sharp chips to fly into your face or hands.
Besides the ways, all other unpainted and machined surfaces should be wiped down daily to keep them rust-free and in top condition. This includes any surface that is vulnerable to rust if left unprotected (especially any parts that are exposed to water-soluble coolant). Typically, a thin film of oil is all that is necessary for protection.
-64-
Page 67
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
MAINTENANCE
www.southbendlathe.com
s&!8
Lathe Monthly Maintenance Chart
®
Service Item
Change Gearbox Oil
Change Headstock Oil
Change Apron Oil
Change Coolant
South Bend Lathe Co.
Refer to the coolant manufacture's instructions for more information regarding coolant condition, replacement, dis-
posal, and safety.
12345678910111213141516171819202122232425262728293031
Day
Annual Service
Item
Lubrication
Ways
Ball Oilers
Leadscrew
Unpainted
Surfaces
Inspection
Headstock
Oil Level
Gearbox
Oil Level
Apron Oil
Level
Coolant
Level
Coolant
Condition
Use this chart to keep track of the maintenance performed on your South Bend Lathe. Cross out or initial the “Day” box for each item on the list.
If the box is blacked out, maintenance is not required for that item on that day. Use the maintenance poster included with your South Bend Lathe
as a quick reference guide when performing the maintenance items.
Date of last annual service:
Once every year, or more often with heavy use,
perform these service items. Keep track of when you
last performed your annual service and when you’ll
need to perform it again.
Date of next annual service:
Make copies of this page to use each month. Keep each chart as a maintenance record for your South Bend Lathe.
-65-
Page 68
13" Heavy 13® Gearhead Lathe
The following recommended lubrication schedules are based on light-to-medium usage. Keeping in mind that lubrication helps to protect the value and operation of the lathe, these lubrication tasks may need to be performed more frequently than recommended here, depending on usage.
Failure to follow reasonable lubrication practices as instructed in this manual could lead to premature failure of lathe components and will void the warranty.
MAINTENANCE
Lubrication
For Machines Mfg. Since 5/11
Adding Oil
The oil fill plug is located on top of the headstock, as shown in Figure 100.
Fill Plug
Drain
Plug
Headstock
Oil Type .. Mobil DTE Light or ISO 32 Equivalent
Oil Amount ............................................ 6.4 Quarts
Check/Add Frequency ....................................Daily
Change Frequency ....................... Every 6 Months
The headstock gearing is lubricated by an oil bath that distributes the lubricant with the motion of the gears, much like an automotive manual transmission.
Checking Oil Level
The headstock reservoir has the proper amount of oil when the oil level in the sight glass is approximately halfway. The oil sight glass is located on the right side of the headstock, as shown in Figure 99.
Headstock Oil
Sight Glass
Figure 100. Headstock fill and drain plugs.
Changing Oil
Items Needed Qty
Wrench
Catch Pan 2-Gallon ...............................................1
5
⁄8" .............................................................1
To change the headstock oil:
1. DISCONNECT LATHE FROM POWER!
2. Remove the end gear cover.
3. Remove the V-belts so that oil does not get
on them, necessitating their replacement (refer to the V-Belt subsection on Page 77 for detailed instructions).
4. Remove the fill plug on top of the headstock
to allow the oil to drain more freely.
5. Place the catch pan under the headstock
drain plug (see Figure 100), then remove the plug.
Figure 99. Location of headstock oil sight glass.
-66-
6. When the headstock reservoir is empty,
replace the drain plug and clean away any oil that may have spilled.
7. Fill the headstock reservoir until the oil level
is approximately halfway in the sight glass.
8. Replace and re-tension the V-belts, then
secure the end gear cover before re­connecting the power.
Page 69
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
MAINTENANCE
Quick-Change Gearbox
Oil Type ...... Mobil Vactra 2 or ISO 68 Equivalent
Oil Amount .............................................. 1.4 Quart
Check/Add Frequency ....................................Daily
Change Frequency ...................................Annually
Checking Oil Level
The gearbox reservoir has the proper amount of oil when the oil level in the sight glass is approximately halfway. The oil sight glass is located on the right side of the gearbox, as shown in Figure 101.
Gearbox Oil
Sight Glass
Draining Oil
Place a catch pan under the quick-change gearbox drain plug (see Figure 102), use a wrench to loosen the fill plug and remove the drain plug, then allow the gearbox reservoir to empty.
5
⁄8"
Apron
Oil Type ...... Mobil Vactra 2 or ISO 68 Equivalent
Oil Amount ............................................ 1.2 Quarts
Check/Add Frequency ....................................Daily
Change Frequency ...................................Annually
Checking Oil Level
The apron oil sight glass is on the front of the apron, as shown in Figure 103. Maintain the oil volume so that the level is approximately halfway in the sight glass.
Figure 101. Location of quick-change gearbox oil sight
glass.
Adding Oil
Use a 5⁄8" wrench to remove the gearbox fill plug (see Figure 102), then add the oil until the level is approximately halfway in the gearbox oil sight glass.
Fill
Plug
Drain
Plug
Sight Glass
Figure 103. Location of apron oil sight glass.
Draining Oil & Flushing Reservoir
Since the apron oil reservoir supplies the one­shot oiler, the oil is constantly being refreshed when the reservoir is filled. However, small metal particles may accumulate at the bottom of the reservoir with normal use. Therefore, to keep the reservoir clean, drain and flush it at least once a year.
Figure 102. Locations of the quick-change gearbox fill
and drain plugs.
-67-
Page 70
13" Heavy 13® Gearhead Lathe
Place a catch pan under the apron drain plug shown in Figure 104, loosen the fill plug, then use a 6mm hex wrench to remove the drain plug and empty the reservoir.
Drain Plug
Figure 104. Location of apron drain plug.
MAINTENANCE
For Machines Mfg. Since 5/11
One-Shot
Oiler
Figure 105. Location of one-shot oiler on the apron.
Longitudinal Leadscrew
Oil Type ...... Mobil Vactra 2 or ISO 68 Equivalent
Oil Amount ............................................ As Needed
Lubrication Frequency ................................... Daily
Flush the reservoir by pouring a small amount of clean oil into the fill hole and allowing it to drain out the bottom.
Replace the drain plug and add oil as previously described.
One-Shot Oiler
The one-shot oiler shown in Figure 105 lubricates the saddle ways with oil from the apron reservoir.
To use the one-shot oiler, pull the pump knob out for two or three seconds and then push it in. The pump draws oil from the apron reservoir and then forces it through drilled passages to the way guides.
Repeat this process while moving the carriage and cross slide through their full range of movement to distribute oil along the ways.
Before lubricating the leadscrew, clean it first with mineral spirits. A stiff brush works well to help clean out the threads. Make sure to move the carriage out of the way, so you can clean the entire length of the leadscrew.
Apply a thin coat of oil along the length of the leadscrew. Use a stiff brush to make sure the oil is applied evenly and down into the threads.
Note: In some environments, abrasive material can become caught in the leadscrew lubricant and drawn into the half nut. In this case, lubricate the leadscrew with a quality dry lubricant.
Lubricate the ways before and after operating the lathe. If the lathe is in a moist or dirty environment, increase the lubrication interval.
Check the apron oil level through the sight glass before using the one-shot oiler.
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Page 71
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
MAINTENANCE
Ball Oilers & Oil Cup
Oil Type .. Mobil DTE Light or ISO 32 Equivalent
Oil Amount ................................ 1 or 2 Squirts/Fill
Lubrication Frequency ................................... Daily
This lathe has seven ball oilers and one oil cup that should be oiled on a daily basis before beginning operation.
Proper lubrication of ball oilers is done with a pump-type oil can that has a plastic or rubberized cone tip. We do not recommend using metal needle or lance tips, as they can push the ball too far into the oiler, break the spring seat, and lodge the ball in the oil galley.
Lubricate the ball oilers before and after machine use, and more frequently under heavy use. When lubricating ball oilers, first clean the outside surface to remove any dust or grime. Push the rubber or plastic tip of the oil can nozzle against the ball oiler to create a hydraulic seal, then pump the oil can once or twice. If you see sludge and contaminants coming out of the lubrication area, keep pumping the oil can until the oil runs clear. When finished, wipe away any excess oil.
A. Cross Slide Leadscrew & Nut B. Compound Rest Leadscrew & Nut C. Feed Selection Lever Gearing D. Cross Slide Leadscrew Bearing
E
Figure 107. Tailstock ball oilers.
E. Quill Barrel F. Quill Leadscrew & Nut
F
For the oil cup, lift the lid and fill the cup to the top. The oil will slowly drain into the gearing over time.
Refer to Figures 106–108 and the following descriptions to identify the locations of each oil device.
A
B
C
D
Figure 106. Carriage ball oilers and oil cup.
G
H
Figure 108. Leadscrew and feed rod end bearing ball
oilers.
G. Leadscrew End Bearing H. Feed Rod End Bearing
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Page 72
13" Heavy 13® Gearhead Lathe
MAINTENANCE
For Machines Mfg. Since 5/11
End Gears
Grease Type ............................................... NLGI#2
Frequency ................ Annually or When Changing
The end gears, shown in Figure 109, should always have a thin coat of heavy grease to minimize corrosion, noise, and wear. Wipe away excess grease that could be thrown onto the V-belts and reduce optimal power transmission from the motor.
Figure 109. End gears.
Handling & Care
Make sure to clean and lubricate any gears you install or change. Be very careful during handling and storage—the grease coating on the gears will easily pickup dirt or debris, which can then spread to the other gears and increase the rate of wear.
Lubricating
1. DISCONNECT LATHE FROM POWER!
2. Remove the end gear cover and all the end
gears shown in Figure 109.
3. Clean the end gears thoroughly with mineral
spirits to remove the old grease. Use a small brush if necessary to clean between the teeth.
4. Clean the shafts, and wipe away any grease
splatters in the vicinity and on the inside of the end gear cover.
5. Using a clean brush, apply a thin layer of
grease on the gears. Make sure to get grease between the gear teeth, but do not fill the teeth valleys.
6. Install the end gears and mesh them
together with an approximate 0.002" backlash. Once the gears are meshed together, apply a small dab of grease between them where they mesh together— this grease will be distributed when the gears rotate and re-coat any areas scraped off during installation.
7. Re-install the end gear cover before re-
connecting the lathe to power.
Make sure the end gear cover remains installed whenever possible to keep the gears free of dust or debris from the outside environment.
-70-
Page 73
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
Coolant System Service
The coolant system consists of a fluid tank, pump, and flexible nozzle. The pump pulls fluid from the tank and sends it to the valve, which controls the flow of coolant to the nozzle. As the fluid leaves the work area, it drains back into the tank through the chip drawer and catch tray where the swarf is screened out.
MAINTENANCE
Although most swarf from machining operations is screened out of the coolant before it returns to the tank, small particles will accumulate in the bottom of the tank in the form of sludge. To prevent this sludge from being pulled into the pump and damaging it, the pump’s suction tube is positioned a couple inches from the bottom of the tank and fitted with a fine screen. This works well when the tank is regularly cleaned; however, if too much sludge is allowed to accumulate before the tank is cleaned, the pump will inevitably begin sucking it up.
Use Figures 110–111 to identify the locations of the coolant system controls and components.
Coolant
Pump
Switch
Figure 110. Coolant controls.
Pump & Reservoir
(Inside Cabinet)
Nozzle & Valve Lever
Catch
Tray
Chip Drawer
Hazards
As coolant ages and gets used, dangerous microbes can proliferate and create a biological hazard. The risk of exposure to this hazard can be greatly reduced by replacing the old fluid on a monthly basis, or as indicated by the fluid manufacturer.
The important thing to keep in mind when working with the coolant is to minimize exposure to your skin, eyes, and lungs by wearing the proper PPE (Personal Protective Equipment), such as splash-resistant safety goggles, long­sleeve waterproof gloves, protective clothing, and a NIOSH approved respirator.
BIOLOGICAL & POISON
HAZARD! Use the correct personal protection equipment when handling coolant. Follow federal, state, and fluid manufacturer requirements for proper disposal.
Figure 111. Additional coolant components.
-71-
Page 74
13" Heavy 13® Gearhead Lathe
MAINTENANCE
For Machines Mfg. Since 5/11
Adding Fluid
1. DISCONNECT LATHE FROM POWER!
2. Remove the vented access cover from the
rear of the right stand, then slide the tank out, as shown in Figure 112.
Pump
Fluid Hose
Tank
Figure 112. Coolant tank and pump.
3. Pour coolant into the tank until it is nearly
full.
Electrical
Conduit
To change the coolant:
1. Position the coolant nozzle over the back of
the back splash so that it is pointing behind the lathe.
2. Place the 5-gallon bucket behind the lathe
and under the coolant nozzle. If you are using the optional hose, connect it to the nozzle and place it in the bucket. Otherwise, you may need to have another person hold the bucket up to the nozzle to prevent coolant from splashing out.
3. Turn the coolant pump ON and pump the
old fluid out of the reservoir. Turn the pump OFF immediately after the fluid stops flowing.
Running the coolant pump without adequate fluid in the tank may permanently damage it, which will not be covered under warranty.
4. DISCONNECT LATHE FROM POWER!
4. Slide the tank back into the cabinet and
replace the access cover.
Changing Coolant
When you replace the old coolant, take the time to thoroughly clean out the chip drawer, catch tray, and fluid tank. The entire job only takes about a proper materials and tools. Make sure to dispose of old fluid according to federal, state, and fluid manufacturer's requirements.
Items Needed: Qty
Safety Wear .................. See Hazards on Page 71
New Coolant ........................................ 11.1 Quarts
Empty 5-Gallon Bucket w/Lid ..............................2
Phillips Screwdriver #2 ........................................1
Wrench
Disposable Shop Rags ........................... As Needed
Hose or Tubing
Magnets (Optional) ............... As Many As Desired
1
⁄2 hour when you are prepared with the
3
⁄4" .............................................................1
5
⁄8" x 60" (Optional) ........... 1 Piece
5. Remove the vented access cover from the
rear of the right stand, then slide the tank out.
6. To enable the remaining fluid to be poured
out in the next step, disconnect the fluid hose from the pump (see Figure 112).
Note: The electrical conduit was purposely
left long, so the tank can be removed and dumped out without disconnecting the wires from the pump.
7. Pour the remaining coolant into the 5-gallon
bucket and close the lid.
8. Clean all the sludge out of the bottom of the
tank and then flush it clean. Use the second bucket to hold the waste and make sure to seal the lid closed when done.
Dispose of the old coolant and swarf
according to federal, state, and fluid manufacturer's requirements.
-72-
Page 75
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
MAINTENANCE
9. Slide the tank partially into the base and re-
connect the fluid hose.
Tip: Leave one or more magnets at the bottom
of the tank to collect metal chips and make cleanup easier next time. This will also help keep small metal chips out of the pump.
10. Refill the tank with new coolant, then slide it
completely into the base.
11. Replace the access cover panel.
12. Re-connect the lathe to power and point the
nozzle into the chip drawer.
13. Turn the master power switch ON, then
reset the STOP button.
14. Turn the coolant pump ON to verify that
fluid cycles properly, then turn it OFF.
Machine Storage
To prevent the development of rust and corrosion, the lathe must be properly prepared if it will be stored for a long period of time. Doing this will ensure the lathe remains in good condition for later use.
To prepare the lathe for storage:
1. Run the lathe and bring all gearboxes to
operating temperature, then drain and refill them with clean oil.
2. Pump out the old coolant, then add a few
drops of way oil and blow out the lines with compressed air.
4. Thoroughly clean all unpainted, bare metal
surfaces, then apply a liberal coat of way oil, heavy grease, or rust preventative. Take care to ensure these surfaces are completely covered but that the rust preventative or grease is kept off of painted surfaces.
5. Lubricate the machine as outlined in the
lubrication section. Be sure to use an oil can to purge all ball oilers and oil passages with fresh oil.
6. Loosen or remove the V-belts so they do not
become stretched during the storage period. (Be sure to place a maintenance note near the power button as a reminder that the belts have been loosened or removed.)
7. Place a few moisture absorbing desiccant
packs inside of the electrical box.
8. Cover the lathe and place it in a dry area
that is out of direct sunlight and away from hazardous fumes, paint, solvents, or gas. Fumes and sunlight can bleach or discolor paint and make the chuck guard cloudy.
9. Every few months, rotate by hand all gear-
driven components a few times in several gear selections. This will keep the bearings, bushings, gears, and shafts well lubricated and protected from corrosion—especially during the winter months.
Slide the carriage, micrometer stop,
tailstock, and steady rest down the lathe bed to make sure that way spotting is not beginning to occur.
3. DISCONNECT LATHE FROM POWER!
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Page 76
13" Heavy 13® Gearhead Lathe
SERVICE
For Machines Mfg. Since 5/11
Backlash Adjustment
Backlash is the amount of free play felt while changing rotation directions with the handwheel. This can be adjusted on the compound rest and cross slide leadscrews. Before beginning any adjustment, make sure that all associated components have been cleaned and lubricated.
Reducing backlash to less than 0.002" is impractical and can lead to accelerated wear of the wedge, nut, and leadscrew. Avoid the temptation to overtighten the backlash set screw while adjusting.
Compound Rest
Tools Needed: Qty
Hex Wrench 3mm .................................................1
The compound rest backlash is adjusted by tightening the set screws shown in Figure 113. When these screws are adjusted against the leadscrew nut, they offset part of the nut to remove play between the nut and leadscrew.
Cross Slide
Tools Needed: Qty
Hex Wrench 3mm .................................................1
Hex Wrench 5mm ................................................1
The cross slide backlash is adjusted by loosening all four cap screws shown in Figure 114, then tightening the center set screw. This will push down on a wedge and force the leadscrew nut apart, taking up lash between the nut and leadscrew.
Cap Screws
Set
Screw
Figure 114. Cross slide backlash adjustment screws.
Set Screws
Figure 113. Compound rest backlash adjustment set
screws.
To adjust the backlash, rock the handwheel back and forth, and tighten the screws slowly until the backlash is approximately 0.002"–0.003", as indicated on the graduated dial.
If you end up adjusting the nut too tight, loosen the set screws, tap the compound rest a few times with a rubber or wooden mallet, and turn the handwheel slowly back and forth until it moves freely—then try again.
To adjust the backlash, remove the compound rest and loosen the four cap screws. Then, rock the cross slide handwheel back and forth, and tighten the set screw slowly until the backlash is at approximately 0.002"–0.003" as indicated on the graduated dial.
If you end up adjusting the nut too tight, loosen the set screw, tap the cross slide a few times with a rubber or wooden mallet, and turn the handwheel slowly back and forth, until the handle turns freely—then try again.
Remember to re-tighten the four cap screws when you are finished.
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For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
SERVICE
Leadscrew End Play Adjustment
After a long period of time, you may find that the leadscrew develops a small amount of end play. This end play can be removed with an easy adjustment.
Tools Needed: Qty
Hex Wrench 3mm .................................................1
Wrench 24mm ......................................................1
To remove leadscrew end play:
1. DISCONNECT LATHE FROM POWER!
2. Loosen the two set screws in the leadscrew
end nut (see Figure 115).
End Nut
& Set Screws
Gib Adjustment
The goal of adjusting the gib screws is to remove sloppiness or "play" from the ways without over­adjusting them to the point where they become stiff and difficult to move.
In general, loose gibs cause poor finishes and tool chatter; however, over-tightened gibs cause premature wear and make it difficult to turn the handwheels.
Important: Before adjusting the gibs, loosen the locks for the device so that the gibs can freely slide during adjustment, then lubricate the ways.
The gibs are tapered and held in position by a screw at each end. To adjust the gib, turn one screw turn counterclockwise, so both screws move in the same direction and the same amount. Test the feel of the sliding component by turning the handwheel, and adjust the gib screws as necessary to make it tighter or looser.
1
⁄4 turn clockwise and the other screw 1⁄4
Figure 115. Leadscrew end nut.
3. Engage the half nut with the leadscrew.
4. Use the handwheel to move the carriage
slightly toward the tailstock, then tighten the end nut at the same time until the end play is removed.
5. Retighten both set screws.
The gib adjustment process usually requires some trial-and-error. Repeat the adjustment process as necessary until you find the best balance between loose and stiff movement. Most machinists find that the ideal gib adjustment is one where a small amount of drag or resistance is present, yet the handwheels are still easy to move.
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13" Heavy 13® Gearhead Lathe
SERVICE
For Machines Mfg. Since 5/11
Figures 116–120 show the location of the adjustment screws for each gib on this machine.
Compound Rest
Gib Adjustment Screw
(1 of 2)
Cross Slide
Gib Adjustment Screw
(1 of 2)
Figure 116. Compound and cross slide gib adjustment
screws.
Note: Remove the thread dial body and the
carriage lock clamp to access the saddle gib adjustment screw on the tailstock side (see Figure 119).
Carriage
Lock
Clamp
Figure 119. Carriage lock clamp.
Note: Before adjusting the tailstock gib, loosen
the clamping hex bolts underneath both ends of the tailstock (see Figure 120) to release the clamping pressure between the upper and lower castings. Test the gib adjustment by using the offset adjustment screws. When you are satisfied with the setting, retighten the clamping hex bolts.
Saddle Rear
Gib Adjustment
Screw (1 of 2)
Figure 117. One of two rear saddle gib adjustment
screws.
Gib Adjustment
Screw (1 of 2)
Figure 118. Front saddle gib adjustment screw.
Offset Adjustment
Screw (1 of 2)
Gib Adjustment
Screw (1 of 2)
Figure 120. Tailstock gib adjustment controls.
Clamping Hex
Bolt (1 of 2)
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Page 79
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
SERVICE
Half Nut Adjustment
The clamping pressure of the half nut is fully adjustable with a gib that can be loosened or tightened by two set screws. Use this procedure to adjust the half nut if it becomes loose from wear, or it is too tight for your preferences. A half nut that is too loose will make it difficult to produce accurate work. A half nut that is too tight will increase the rate of wear on itself and the leadscrew.
Tool Needed: Qty
Hex Wrench 3mm .................................................1
To adjust the half nut:
1. Disengage the half nut, then remove the
thread dial.
2. Turn the two set screws (see Figure 121)
clockwise to tighten the half nut and counterclockwise to loosen it.
V-Belts
V-belts stretch and wear with use, so check the tension on a monthly basis to ensure optimal power transmission. Replace all of the V-belts as a matched set if any of them show signs of glazing, fraying, or cracking.
Tools Needed: Qty
Phillips Screwdriver #2 ........................................1
Open End Wrench 24mm......................................1
To adjust the V-belts:
1. DISCONNECT LATHE FROM POWER!
2. Remove the end gear cover and the motor
access panel to expose the V-belts and pulleys (see Figure 122).
Note: Make sure to turn the set screws in even
amounts so that one end of the gib does not become tighter than the other.
Set
Screws
Figure 121. Half nut gib adjustment.
3. Engage/disengage the half nut several times
and notice how it feels. The half nut is correctly adjusted when it has a slight drag while opening and closing. The movement should not be too stiff or too sloppy.
End Gear Cover
Motor Access
Panel
4. Repeat Steps 2–3, if necessary, until you are
satisfied with the half nut pressure.
5. Re-install the thread dial.
Figure 122. End gear cover and motor access panel.
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13" Heavy 13® Gearhead Lathe
SERVICE
3. Adjust the hex nuts on the motor mount
bolts shown in Figure 123, until there is
3
approximately
⁄4" deflection of the V-belts when moderate pressure is applied midway between the pulleys.
For Machines Mfg. Since 5/11
Brake & Switch
As the brake lining wears, the foot pedal develops more travel. If the brake band is not adjusted to compensate for normal wear, the limit switch will still turn the lathe off, but the spindle will not stop as quickly. It is especially important that the brake is kept properly adjusted so you can quickly stop the spindle in an emergency.
Tools Needed: Qty
Phillips Screwdriver #2 ........................................1
Hex Wrench 6mm .................................................1
Motor Mount
Hex Nuts & Bolts
Pulley
Deflection
Pulley
Figure 123. Adjusting V-belt tension.
4. Firmly tighten the hex nuts to secure the
setting, then re-install the covers.
To adjust the brake and brake switch:
1. DISCONNECT LATHE FROM POWER!
2. Put on a respirator and eye protection to
protect yourself from hazardous brake dust.
3. Remove the motor access panel from the left
cabinet.
4. Measure the remaining brake band lining at
the thinnest point, which is usually at the 8 o'clock position, as shown in Figure 124.
3mm
-78-
Figure 124. Minimum brake belt thickness.
When the brake band is new, the lining
is approximately 6mm thick. If the lining thickness wears to 3mm or less, the brake band must be replaced. Otherwise, the rivets that secure the lining to the band will soon grind into the brake hub. If the hub becomes damaged, it must be replaced.
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For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
SERVICE
5. Remove the pedal stop shown in Figure 125.
Pedal Lever
Brake Belt
Band
Pedal Stop
Figure 125. Brake belt adjustment components.
6. Move the brake band to the right one hole,
and re-install the pedal stop, tightening the cap screw until it is just snug.
Note: If installing a new brake band, install the
cap screw so there is one hole to the left for future brake adjustment.
7. Firmly push the pedal lever to the right until
it stops and the brake band is fully clamped around the brake hub.
8. Tap the pedal stop into position so there
is approximately a 25mm gap between the pedal lever and the stop (see Figure 126), then firmly tighten the pedal stop cap screw.
Pedal
Stop
Pedal Lever
9. Locate the brake switch shown in
Figure 127.
Brake
Switch
Pedal
Cam
Figure 127. Brake switch and pedal cam.
10. Push the pedal lever down to verify that the
cam lobe pushes the brake switch plunger in. When pushed in, the switch should click.
— If the switch does not click, loosen the
switch mounting screws, push the brake pedal all the way down, and move the switch closer to the lobe until it clicks. Secure the switch in place at this location.
Note: In the released position, there should be an
approximate 3mm gap between the switch plunger and the cam lobe.
11. Re-install the motor access panel, connect
the lathe to power, then test the brake pedal. If you are not satisfied with the brake performance, repeat this procedure until you are.
Figure 126. Brake pedal travel adjustment.
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Page 82
13" Heavy 13® Gearhead Lathe
SERVICE
For Machines Mfg. Since 5/11
Leadscrew Shear Pin Replacement
The leadscrew is secured to a connecting collar that is part of the headstock drivetrain with the use of a soft-metal shear pin. The shear pin is designed to break and disengage the power transfer to the leadscrew to help protect more expensive lathe components in the case of a carriage crash or the lathe is overloaded.
Contact South Bend to order a replacement shear pin (Part Number PSB10121234) or use the specifications in Figure 128 to fabricate your own.
9mm
7mm
To replace the shear pin:
1. DISCONNECT LATHE FROM POWER!
2. Rotate the shroud washer on the leadscrew
shown in Figure 129, so that the cutout lines up with the shear pin head.
Shear Pin
Head
Cutout
Figure 129. Shroud washer and shear pin alignment.
Shroud Washer
5.8mm
0.2mm
NOTE: Shear Pin Material = S45C (SAE 1045)
Figure 128. Shear pin specifications.
0.2mm
3mm
0.5mm
Tools Needed: Qty
External Retaining Ring Pliers #1 ....................... 1
Magnet ................................................................... 1
Safety Goggles ....................................................... 1
Blow Gun w/Compressed Air ................................ 1
Light Machine Oil .................................. As needed
If you fabricate your own shear pin, make sure to use the material and dimensions specified in Figure 128. Otherwise, the shear pin may not provide the intended protection and lathe damage could result.
3. Put on safety glasses.
4. Move the retaining ring shown in Figure
130 away from the shroud washer.
Figure 130. Shear pin access.
5. To make enough room to remove the shear
pin, move the shroud washer away from the shear pin and against the retaining ring, as shown in Figure 130.
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For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
SERVICE
6. Use the magnet to remove the shear pin
head, then rotate the lathe spindle to line
Shear Pin
up the inner and outer bores, as shown in Figure 131. Next, use the magnet to remove the other half of the broken shear pin when it becomes visible.
Inner Bore
Figure 132. New shear pin installed in bore.
9. With the pin completely seated in the bore
Outer Bore
and the head flush with the leadscrew shoulder, slide the shroud washer against the shoulder, then rotate the washer 180° to
Figure 131. Shear pin bores aligned.
completely cover the head of the shear pin, as shown in Figure 133.
7. Insert the blow gun tip into the shear pin
hole, blow out the hole with compressed air, then put a drop of oil in the hole.
8. Insert the new shear pin into the bore, as
shown in Figure 132.
Note: If the pin does not freely slide into the
bore, DO NOT use a hammer on the pin or you may permanently damage the shear mechanism and bore, which would make it nearly impossible to remove and install a new shear pin later.
Instead, take the time to carefully line up
the two bores. You may need to file a slight chamfer on the end of the pin to make it easier to insert.
Rotate
Washer
Slot 180°
Figure 133. Shroud washer positioning.
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Page 84
13" Heavy 13® Gearhead Lathe
SERVICE
For Machines Mfg. Since 5/11
10. Return the retaining ring against the shroud
washer and position the retaining ring ears over the shear pin head, as shown in Figure 134. This will prevent the shear pin from falling out if the shroud washer should rotate during operation.
Figure 134. Retaining ring positioned with ears in
front of pin access groove.
Tools Needed: Qty
Hex Wrenches 6mm .............................................. 1
Hex Wrench 8mm .................................................1
Wrench 17mm .......................................................1
Dead Blow Hammer .............................................. 1
Gap Removal
1. Remove the four gap-bed cap screws, shown
in Figure 136.
Dowel Pin
Jack Nut
Gap-Bed
Cap Screw
Way End
Cap Screw
Figure 136. Fasteners holding gap in place.
Gap Insert Removal & Installation
The gap insert directly under the spindle (see Figure 135) can be removed to create additional space for turning large diameter parts.
The gap insert was installed, then ground flush with the bed at the factory to ensure a precision fit and alignment. Therefore, if the gap insert is removed, it may be difficult to re-install with the same degree of accuracy.
2. Remove the two way-end cap screws.
3. Tighten the two dowel-pin jack nuts until the
pins are pulled free from the gap insert.
4. Tap the outside of the gap insert with a dead
blow hammer to loosen it, then remove it.
-82-
Gap Insert
Figure 135. Gap insert.
Page 85
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
SERVICE
Gap Installation
1. Use mineral spirits and a clean lint-free rag
to clean the mating surfaces of the gap, bed, and ways. If necessary, stone the mating surfaces to remove scratches, dings, or burrs.
2. Wipe a thin layer of light machine oil on the
mating surfaces.
3. Place the gap insert into the gap and use a
dead-blow hammer to align the insert with the lathe bed.
4. Back off the dowel pin jack nuts, and lightly
tap the dowel pins back into their respective holes until they are seated. This process will further help align the gap insert and bed mating surfaces.
5. Install all fasteners and lightly snug them in
place.
6. Mount a dial indicator with a magnetic base
to the top of the saddle to indicate alignment.
7. First test the peak of the two prisms of the
gap insert that the saddle rides on, then test the flanks of the prisms.
8. Tighten the gap bed cap screws in an
alternating manner and tap the side of the gap insert into alignment.
9. Inspect the gap alignment 24 hours later
to make sure the gap is still aligned. If necessary, loosen the gap bed cap screws and repeat Steps 7–8 until the insert is properly aligned.
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Page 86
13" Heavy 13® Gearhead Lathe
TROUBLESHOOTING
For Machines Mfg. Since 5/11
If you need replacement parts, or if you are unsure how to do any of the solutions given here, feel free to call us at (360) 734-1540.
Symptom Possible Cause Possible Solution
Machine does not start or a circuit breaker trips.
1.
(First time operation only) Lathe is wired out of phase.
2.
STOP button is engaged or at fault.
3.
Spindle switch(es) are at fault.
4.
Power supply is switched OFF at master power switch or breaker.
5.
Wall fuse/circuit breaker is blown/ tripped; short in electrical system; start-up load too high for circuit.
6.
Fuse has blown in machine electrical box.
7.
One or more safety switches or brake switch are engaged.
8.
Thermal overload relay has tripped.
9.
Motor connection wired incorrectly.
10.
Safety/brake switch(es) at fault.
11.
Contactor not getting energized/has burned contacts.
12.
Wiring is open/has high resistance.
13.
Motor is at fault.
1.
Swap two hot wire connections on master switch (see Page 25).
2.
Rotate button clockwise until it pops out to reset it for operation; replace if not working properly.
3.
Replace bad switch(es).
4.
Make sure master power switch and circuit breaker are turned ON.
5.
Verify circuit is rated for machine amp load; troubleshoot and repair cause of overload; replace weak breaker; find/repair electrical short.
6.
Replace fuse; determine if overload is due to heavy operation; ensure power source has high enough voltage and power cord is correctly sized.
7.
Verify electrical box door, chuck guard, spindle, and brake switches are not engaged.
8.
Turn the thermal relay cut-out dial to increase working amps and push the reset pin. Replace if tripped multiple times (weak relay).
9.
Correct motor wiring connections.
10.
Test all switches and replace as necessary.
11.
Test for power on all legs and contactor operation. Replace unit if faulty.
12.
Check for broken wires or disconnected/corroded connections, and repair/replace as necessary.
13.
Test/repair/replace.
Loud, repetitious noise coming from lathe at or near the motor.
Motor overheats.
Motor is loud when cutting, or bogs down under load.
1.
Pulley set screws or keys are missing or loose.
2.
Motor fan is hitting the cover.
1.
Motor overloaded.
1.
Excessive depth of cut or feed rate.
2.
Spindle speed or feed rate wrong for cutting operation.
3.
Cutting tool is dull.
1.
Inspect keys and set screws. Replace or tighten if necessary.
2.
Tighten fan, shim cover, or replace items.
1.
Reduce load on motor.
1.
Decrease depth of cut or feed rate.
2.
Refer to the feeds and speeds charts in Machinery's Handbook or a speeds and feeds calculator on the internet.
3.
Sharpen or replace the cutting tool.
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Page 87
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
TROUBLESHOOTING
Symptom Possible Cause Possible Solution
Entire machine vibrates upon startup and while running.
Bad surface finish.
1.
Workpiece is unbalanced.
2.
Loose or damaged V-belt(s).
3.
V-belt pulleys are not properly aligned.
4.
Worn or broken gear present.
5.
Chuck or faceplate is unbalanced.
6.
Gears not aligned in headstock or no backlash.
7.
Broken gear or bad bearing.
8.
Workpiece is hitting stationary object.
9.
Spindle bearings at fault.
1.
Wrong spindle speed or feed rate.
2.
Dull tooling or poor tool selection.
3.
Tool height not at centerline.
4.
Too much play in gibs.
1.
Re-install workpiece as centered with the spindle bore as possible.
2.
Re-tension/replace the V-belt(s) as necessary (see Page 77).
3.
Align the V-belt pulleys.
4.
Inspect gears and replace if necessary.
5.
Re-balance chuck or faceplate; contact a local machine shop for help.
6.
Adjust gears and establish backlash.
7.
Replace broken gear or bearing.
8.
Stop lathe immediately and correct interference problem.
9.
Reset spindle bearing preload or replace worn spindle bearings.
1.
Adjust for appropriate spindle speed and feed rate.
2.
Sharpen tooling or select a better tool for the intended operation.
3.
Adjust tool height to centerline (see Page 47).
4.
Tighten gibs (see Page 75).
Tapered tool difficult to remove from tailstock quill.
Cross slide, compound, or carriage feed has sloppy operation.
Cross slide, compound, or carriage feed handwheel is hard to move.
Cutting tool or machine components vibrate excessively during cutting.
1.
Quill is not retracted all the way back into the tailstock.
2.
Contaminants not removed from taper before inserting into quill.
1.
Gibs are out of adjustment.
2.
Handwheel is loose or backlash is high.
3.
Leadscrew mechanism worn or out of adjustment.
1.
Dovetail slides loaded with shavings, dust, or grime.
2.
Gib screws are too tight.
3.
Backlash setting too tight (cross slide only).
4.
Bedways are dry.
1.
Tool holder not tight enough.
2.
Cutting tool sticks too far out of tool holder; lack of support.
3.
Gibs are out of adjustment.
4.
Dull cutting tool.
5.
Incorrect spindle speed or feed rate.
1.
Turn the quill handwheel until it forces the tapered tool out of quill.
2.
Clean the taper and bore and re-install tapered tool.
1.
Adjust gib screw(s) (see Page 75).
2.
Tighten handwheel fasteners, adjust handwheel backlash to a minimum (see Page 74).
3.
Adjust leadscrew to remove end play (see Page 75).
1.
Remove gibs, clean ways/dovetails, lubricate, and re-adjust gibs.
2.
Loosen gib screw(s) slightly, and lubricate bedways (see Page 75).
3.
Slightly loosen backlash setting (see Page 75).
4.
Lubricate bedways and handles.
1.
Check for debris, clean, and retighten.
2.
Re-install cutting tool so no more than length is sticking out of tool holder.
3.
Adjust gib screws at affected component (see Page
75)
4.
Replace or resharpen cutting tool.
5.
Use the recommended spindle speed.
1
⁄3 of the total
-85-
Page 88
13" Heavy 13® Gearhead Lathe
TROUBLESHOOTING
For Machines Mfg. Since 5/11
Symptom Possible Cause Possible Solution
Workpiece is tapered.
Chuck jaws will not move or do not move easily.
Carriage will not feed, or is hard to move.
Gear change levers will not shift into position.
1.
Headstock and tailstock are not properly aligned with each other.
1.
Chips lodged in the jaws or scroll plate.
1.
Gears are not all engaged.
2.
Loose screw on the feed handle.
3.
Carriage lock is tightened down.
4.
Chips have loaded up on bedways.
5.
Bedways are dry and in need of lubrication.
6.
Micrometer stop is interfering.
7.
Gibs are too tight.
8.
Gears or shear pin broken.
1.
Gears not aligned inside headstock.
1.
Realign the tailstock to the headstock spindle bore centerline (see Page 40).
1.
Remove jaws, clean and lubricate scroll plate, then replace jaws.
1.
Adjust gear levers.
2.
Tighten.
3.
Check to make sure the carriage lock bolt is fully released.
4.
Frequently clean away chips that load up during turning operations.
5.
Lubricate bedways and handles.
6.
Check micrometer stop position, and adjust it as necessary (see Page 48).
7.
Loosen gib screw(s) slightly (see Page 75).
8.
Replace gears or shear pin (see Page 80).
1.
Rotate spindle by hand with light pressure on the lever until gear falls into place.
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Page 89
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
ELECTRICAL
Electrical Safety Instructions
These pages are accurate at the time of printing. In the constant effort to improve, however, we may make changes to the electrical systems of future machines. Study this section carefully. If you see differences between your machine and what is shown in this section, call Technical Support at (360) 734-1540 for assistance BEFORE making any changes to the wiring on your machine.
Shock Hazard: It is extremely dangerous to
perform electrical or wiring tasks while the machine is connected to the power source. Touching electrified parts will result in personal injury including but not limited to severe burns, electrocution, or death. For your own safety, disconnect machine from the power source before servicing electrical components or performing any wiring tasks!
Wire Connections: All connections must be
tight to prevent wires from loosening during machine operation. Double-check all wires disconnected or connected during any wiring task to ensure tight connections.
Modifications: Using aftermarket parts or
modifying the wiring beyond what is shown in the diagram may lead to unpredictable results, including serious injury or fire.
Motor Wiring: The motor wiring shown in these
diagrams is current at the time of printing, but it may not match your machine. Always use the wiring diagram inside the motor junction box.
Circuit Requirements: Connecting the machine
to an improperly sized circuit will greatly increase the risk of fire. To minimize this risk, only connect the machine to a power circuit that meets the minimum requirements given in this manual.
Capacitors/Inverters: Some capacitors and
power inverters store an electrical charge for up to 10 minutes after being disconnected from the power source. To reduce the risk of being shocked, wait at least this long before working on capacitors.
Wire/Component Damage: Damaged wires
or components increase the risk of serious personal injury, fire, or machine damage. If you notice that any wires or components are damaged while performing a wiring task, replace those wires or components before completing the task.
Experiencing Difficulties: If you are
experiencing difficulties understanding the information included in this section, contact our Technical Support at (360) 734-1540.
BLACK
BLUE
BROWN
NOTICE:
WIRING DIAGRAM COLOR KEY
BLUE WHITE
GREEN
GRAY
The photos and diagrams included in this section are best viewed in color. You can see them in color at www.southbendlathe.com.
RED
LIGHT BLUE
ORANGE
PINK
PURPLE
TUR­QUIOSE
WHITE
YEL LOW GREEN
YEL LOW
-87-
Page 90
13" Heavy 13® Gearhead Lathe
Wiring Overview
Chuck Guard
Limit Switch
Page 94
ELECTRICAL
Electrical
Cabinet
Page 90
For Machines Mfg. Since 5/11
Power Supply
Connection
Page 94
Work Lamp
Page 94
Brake Pedal
Micro Switch
Page 94
End Gear Cover
Micro Switch
Page 94
Spindle Motor
Page 92
Spindle
Switches
Page 93
Coolant
Pump Motor
Page 92
Control Panel
Page 93
-88-
Page 91
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
ELECTRICAL
Component Location Index
Electrical
Work Lamp
Page 94
Master Power Switch
Coolant
Pump Motor
Page 92
Cabinet
Page 90
Page 90
Control Panel
Page 93
Chuck Guard
Limit Switch
Page 94
Spindle Switches
(Behind Splash Guard)
Page 93
End Gear Cover
Spindle Motor
Page 92
Micro Switch
Page 94
Brake Pedal
Micro Switch
Page 94
Figure 137. Component location index.
-89-
Page 92
13" Heavy 13® Gearhead Lathe
ELECTRICAL
Electrical Cabinet Wiring
For Machines Mfg. Since 5/11
Ground
To Work Lamp, Page 94
To Chuck Guard Micro Switch, Page 94
3
3
12
L2
L1
L1
135L1 L2 L3
24622T1 T2 T3 NC
25
97 98 NCNO 95 96
2 T1 4 T2 6 T3
U
L1
AB D25
L2
CONTACTOR
Allen Bradley
C2301
AMP
AB 193-T1AC25
RELAY
21
M6 V
L2
L1
1
AB D6
AB D25
23412
L2 L1L1
13
21 NC 21 NC
3
3
3
L1
11
L1
L2
135L1 L2 L3
CONTACTOR
Allen Bradley
C2301
246T1 T2 T3
33
13
L2
12
22 NC
10
L2
L1
3
15
MASTER
POWER SWITCH
2
6
4
L1
L2
L1
L2
L1
1357L1 L2 L3 L4
CONTACTOR Allen Bradley
2468T1 T2 T3 T4
AMP
0.75
97
2 T1 4 T2 6 T3
U1
L1
L2
8
L2
L3
C09400
AB 193-T1AB10
1
RELAY
98 NCNO 95 96
3
3
L3
3
V1
3 5
5 5
6 7
1357L1 L2 L3 L4
CONTACTOR
Allen Bradley
C09400
2468T1 T2 T3 T4
4
11
10
0 220 380 400 415 440
TRANSFORMER
FUSE
4A 250V
Suenn Liang
SP-TBSW-10140
024
3
0 220
0
XXX
FUSE
500MA 250V
X
Ground
UM6V
To Spindle
Motor
Page 92
To Coolant
Pump Motor
Page 92
To Power Supply Connection, Page 94
-90-
U M6 V
U
U M6 U1U1V1
V1
U1 V1
V
U1
M6
V
To End Gear Cover Micro
Page 94
V1
0
Switch
0
0
A1
0
A1
0
A1
A1
To Brake Pedal
Limit Switch
Page 94
33
4
5
6
7
8
7
6
5
4
3
2
1
322111 3
4
2
4
2
5
4
To Control
Page 93
666
7
3
6
8
Panel
8
8
7
5
4
To Spindle
Switches
Page 93
Page 93
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
ELECTRICAL
Electrical Box
Figure 138. Electrical box.
-91-
Page 94
13" Heavy 13® Gearhead Lathe
Spindle Motor
ELECTRICAL
For Machines Mfg. Since 5/11
Run
Capacitor
50MFD
350VAC
1 4
U
Capacitor
V
M6
Spindle
Motor
To Electrical Cabinet
Page 90
Coolant Pump Motor Wiring
To Electrical Cabinet
Page 90
Start
600MFD
250VAC
Ground
-92-
U1
Gn
Ground
V1
Ground
Coolant Pump
Motor
Start Capacitor 3MFD 450VAC
Page 95
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
ELECTRICAL
Control Panel Wiring
Control Panel
Figure 139. Control panel location.
Stop
Button
21
1
2
Spindle Switches
To Electrical Cabinet
1
6
8
3
6
2
3
Jog
Button
4
3
Coolant
Pump
Switch
4
2
X1
X2
Power
Lamp
8
2
2
Page 90
To Electrical Cabinet
Page 90
COMMON
7
NO
Figure 140. Spindle rotation switch location.
NC
NC
NO
COMMON
5
Tend TM-1308
6
4
-93-
Page 96
13" Heavy 13® Gearhead Lathe
COMMON
Tend TM-1307
NC
NO
XA1
0
0
3
1314
2122
NCNCNO
Tend TZ-9212
Tend TM-1704
NO
3
4
X2
A1
X1
4
ELECTRICAL
Additional Component Wiring
End Gear Cover
Safety Switch
Figure 141. End Gear Cover Safety switch location.
For Machines Mfg. Since 5/11
Work Light
End Gear Cover Micro Switch
Figure 141
Chuck Guard
Safety
Switch
Figure 142. Chuck Guard Safety switch location.
Power Connection
Chuck Guard Limit Switch
Figure 142
Brake Pedal Micro Switch
Figure 137
To Electrical
Cabinet
Page 90
Ground
-94-
L2
Hot
Hot
L1
Ground
G
220VAC
L6-30 Plug
(as recommended)
Inside Electrical
Cabinet
Page 90
L2L1
3
1
Master
Power
Switch
2
4
L2L1
5
6
Page 97
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
PARTS
Headstock Cover
1
2
3
4
REF PART # DESCRIPTION REF PART # DESCRIPTION
1 PSB10490001 HEADSTOCK OIL FILL CAP 3 PSB10490003 HEADSTOCK TOP COVER
2PCAP29M CAP SCREW M6-1 X 40 4 PSB10490004 TOP COVER GASKET
-95-
Page 98
13" Heavy 13® Gearhead Lathe
Headstock Controls
PARTS
For Machines Mfg. Since 5/11
60
54
5
7
9
12
61
6
14
15
13
16
28
30
40
17
20
8
6
10
11
21
9
59
58
20
41
54
53
63
62
42
55
9
44
57
42
43
56
46
53
54
18
19
22
24
64
25
21
32
33
23
34
34
28
26
29
27
30
31
35
9
44
36
37
47
48
38
43
50
39
49
45
28
51
47
48
30
49
50
28
52
52
49
51
30
49
-96-
Page 99
For Machines Mfg. Since 5/11 13" Heavy 13® Gearhead Lathe
PARTS
Headstock Controls Parts List
REF PART # DESCRIPTION REF PART # DESCRIPTION
5 PSB10490005 SHIFT FORK 35 PSB10490035 SHAFT
6 PRP06M ROLL PIN 5 X 24 36 PORP018 O-RING 17.8 X 2.4 P18
7 PSB10490007 RIGHT REAR SHIFT LEVER 37 PSB10490037 SHAFT FLAT WASHER 6MM
8 PSB10490008 LEFT REAR SHIFT LEVER 38 PCAP01M CAP SCREW M6-1 X 16
9 PEC015M E-CLIP 8MM 39 PSB10490039 SHAFT END PLUG
10 PCAP04M CAP SCREW M6-1 X 10 40 PSB10490040 COMPRESSION SPRING
11 PSB10490011 SHIFT LEVER FRAME 41 PSB10490041 FEED RANGE SHIFT FORK
12 PSB10490012 SHIFT LEVER ROD 42 PR05M EXT RETAINING RING 15MM
13 PSB10490013 RIGHT FRONT SHIFT LEVER 43 PSB10490043 ROCKER ARM
14 PSB10490014 LEFT FRONT SHIFT LEVER 44 PK155M KEY 3 X 3 X 18
15 PRP02M ROLL PIN 3 X 16 45 PSB10490045 FEED RANGE SHAFT
16 PSB10490016 STEP PIN 46 PSB10490046 FEED DIRECTION SHAFT
17 PR07M EXT RETAINING RING 18MM 47 PORP016 O-RING 15.8 X 2.4 P16
18 PSB10490018 SHIFT CAM 48 PSB10490048 LEVER BRACKET
19 PSB10490019 SPACER 49 PCAP10M C
20 PCAP17MCAP SCREW M4-.7 X 10 50 PSB10490050 LEVER
21 PSB10490021 GEAR 40T 51 PSB10490051 COMPRESSION SPRING
22 PSB10490022 SELECTOR BRACKET 52 PSB10490052 LEVER FLAT WASHER 5MM
23 PCAP02M CAP SCREW M6-1 X 20 53 PLW05M LOCK WASHER 12MM
24 PORP044 O-RING 43.7 X 3.5 P44 54PCAP92M CAP SCREW M12-1.75 X 40
25 PSB10490025 SPEED RANGE SELECTOR 55 PSB10490055 OIL SIGHT GLASS 3/4"
26 PCAP50M CAP SCREW M5-.8 X 10 56 PSB10490056SHAFT
27 PSB10490027 SPEED RANGE HANDLE 57 PORP014 O-RING 13.8 X 2.4 P14
28 PSTB001 STEEL BALL 1/4 58 PSB10490058 SWING SHIFT LEVER
29 PSB10490029 COMPRESSION SPRING 59 PR06M EXT RETAINING RING 16MM
30 PSS20M SET SCREW M8-1.25 X 8 60 PSB10490060 SHIFT FORK
31 PSB10490031 SPEED SELECTOR 61 PSB10490061 OIL TUBE 6 X 270MM
32 PSB10490032 SPEED SELECTOR LABEL PLATE 62 PW04M FLAT WASHER 10MM
33 PRIV001M STEEL FLUTED RIVET 2 X 5MM 63 PSB10490063 FEED DIRECTION SHIFT FORK
34 PK101M KEY 6 X 6 X 14 64 PSB10490064 SPEED RANGE INDICATOR
AP SCREW M5-.8 X 15
-97-
Page 100
13" Heavy 13® Gearhead Lathe
PARTS
Headstock Internal Gears
For Machines Mfg. Since 5/11
84
83
82
73
72
69
66
67
68
69
70
71
85
83
88
89
91
86
87
65
97
102
99
98
100
101
103
104
105
79
96
76
74
78
38
75
95
77
38
68
94
93
92
38
106
90
107
108
109
110
111
112
113
114
115
116
117
-98-
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