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MANUAL LATHE

EQUIPMENT MAINTENANCE DESCRIPTION (IRI-MS01-EMD)

INDUSTRIAL RESOURCES, INC.

A TRAINING SERVICES COMPANY

September 2, 2004

©This document is the property of Industrial Resources, Inc. Copies and distribution of this document is prohibitedunless written authorization is granted by Industrial Resources, Inc.



Industrial Resources, Inc. Manual LatheMachine Shop (IRI-MS01-EMD)

Revision 0 – September 2, 2004 Page 1

PREFACE

This Training Equipment Maintenance Description (EMD) has been designed to assist you in

meeting the requirements of Module (IRI-MS01) of the Machine Shop Training Program. It

contains information about the Manual Lathe. This includes function, quantity of parts, location of

parts, description of the physical construction of the part, and description of the operation of the

part, equipment preventive and corrective maintenance, and references.

You should review each chapter objective. In doing so you will be better prepared to learn the

required information. You should also inspect the equipment, identifying its components and

controls. Should you have additional question about the equipment, ask your supervisor.

A separate document, Manual Lathe Equipment Maintenance Procedure (IRI-MS01-EMP), covers

detailed maintenance of the Manual Lathe.





MANUAL LATHE

TRAINING EQUIPMENT MAINTENANCE DESCRIPTION

TABLE OF CONTENTS

1.0 Introduction......................................................................................................................... 5

1.1 Equipment Function............................................................................................................ 5

1.2 Equipment Description ....................................................................................................... 5

1.2.1 Equipment Data ................................................................................................................ 13

1.3 Equipment Connections and Interface .............................................................................. 14

2.0 Equipment Major Parts ..................................................................................................... 15

2.1 Lathe Bed and Ways ......................................................................................................... 15

2.2 Headstock ......................................................................................................................... 16

2.3 Speed Change Gears (Spindle RPM)................................................................................ 18

2.4 Feed and Thread Pitch Change Gears............................................................................... 19

2.5 Carriage ......................................................................................................................... 26

2.6 Cross Slide ........................................................................................................................ 29

2.7 Compound ......................................................................................................................... 30

2.8 Thread Chasing Dial ......................................................................................................... 312.9 Tailstock and Steady Rest................................................................................................. 32

2.10 Coolant System ................................................................................................................. 34

2.11 Digital Readout (DRO)..................................................................................................... 36

3.0 Equipment Preventive and Corrective Maintenance......................................................... 38

3.1 Preventive Maintenance.................................................................................................... 38

3.2 Corrective Maintenance .................................................................................................... 38

4.0 References ......................................................................................................................... 39





List of Figures:

Figure 1 – Sharp Model 1764T Manual Lathe

Figure 2 – Lathe Chucks, Face Plate and Steady RestFigure 3 – Parts of Carriage Assembly

Figure 4 – Carriage Operating Controls

Figure 5 – Headstock

Figure 6 – Speed and Feed Charts and Gear Change Levers

Figure 7 – Tailstock

Figure 8 – Digital Readout (DRO)

Figure 9 – Power Panel

Figure 10 – Lathe Bed and Ways


Figure 12 – Spindle/Gear Drive Arrangement

Figure 13 – Spindle Speed Selection

Figure 14 – Feed and Thread Change Levers

Figure 15 – Carriage Feed Drive Bars

Figure 16 – Threading Lead Screw and Chasing Dial

Figure 17 – Feed Selection ArrangementFigure 18 – Thread Chasing Mechanism

Figure 19 – Oil Pump and Oil Sight Glass

Figure 20 – Carriage and Cross Slide Controls

Figure 21 – Adjustable Position Feed Stops

Figure 22 – Carriage Feed Stop Lever

Figure 23 – Compound Rest

Figure 24 – Thread Chasing Dial


Figure 26 – Steady Rest

Figure 27 – Coolant Feed Line

Figure 28 – Coolant Controls






List of Tables

Table 1 – Longitudinal (Carriage) Feeds Per Revolution

Table 2 – Cross (Cross Slide) Feeds Per Revolution

Table 3 – English Threads (Threads Per Inch)

Table 4 – Metric Threads (Threads Per Millimeter)

Table 5 – Metric Threads (Threads Per Millimeter)

Table 6 – Module Threads (Screw Threads)





1.0 Introduction

Chapter Objectives:

Describe the functions of the Manual Lathe.1. State, from memory, the functions of the Manual Lathe.

2. Draw a simplified Manual Lathe diagram. Describe the flow path and how the

Manual Lathe performs its function.

3. List the normal Manual Lathe operating parameters.

1.1 Equipment Function

The function of the Manual Engine Lathe is to perform machining operations, such as turning,

boring, threading, and facing, on metallic or nonmetallic work pieces.

1.2 Equipment Description

Manufactured by Sharp Industries Inc., the Manual Lathe is a Sharp, Model 1764T Gap Bed Lathe

(Figure 1 ). The lathe is located in the Machine Shop, and has a design capacity for threading or

turning round stock up to 8 7/8-inches in diameter when supported by the tailstock and facing stock

up to 26-inches located within the gap bed section of the ways.

The gap bed is located close to the chuck and, as the carriage cross slide will not go under any

material that is larger than 8 7/8-inches in diameter, this limits the ability of the lathe to do much

more than “face” material that is too large in diameter.

With a proper tool setup some machining of the larger diameters allowed by the gap bed can be

accomplished, however, the farther the tool is from the tool holder/support the less material can

be removed at each pass of the tool an the more susceptible the operation is to tool chatter and/or

rough surface finish on the work piece.





Gap Bed Section of Ways

Figure 1 – Sharp Model 1764T Manual Lathe

Operation of the lathe is accomplished through the use of many levers, gear sets, lead screws and

other devices. The lather is equipped with three (3) different sized and types of chucks as seen inFigure 2 .

Figure 2 – Lathe Chucks, Face Plate and Steady Rest





The lathe is comprised of numerous parts whose combined function is allow the operator to

produce finished machine products and/or parts that are precision/precise in size. The carriage

assembly consists of those parts labeled in Figures 3 and 4.

Figure 3 – ON/OFF Switch

Carriage

Cross Slide

Compound

Tool Holder

Cross SlideManual FeedHandwheelCarriage Manual Feed Handwheel

Compound FeedHandwheel

Figure 3 – Parts of Carriage Assembly





Spindle Control

Feed Selection Push-Pull

Forward/Reverse Push-Pull

Carriage Gear Oil Level

Feed Engage Lever

Thread Dial

Thread Engage Lever

Figure 4 – Carriage Operating Controls

The carriage controls, control all but the changing of gears in the headstock. The direction of

feed, selection of feed component (cross slide or carriage), threading and starting of the spindle

(once the power is turned on) is controlled from levers and/or push-pull knobs located on the

carriages front apron as seen in Figure 4 . The carriage gears are lubricated from within the

carriage itself and the oil level is displayed in a bull’s-eye type sight glass.

The headstock of the lathe ( Figure 5 ) contains all of the gearing necessary to change spindle

speed, carriage feed and threading selections (threads per inch and thread types). The headstock

gearing is pressure oil through a network of metal tubing that directs lubricant to all required

areas inside the headstock.






The spindle is an integral part of the headstock assembly and, along with the lathe chuck, is the

final drive for the work piece mounted in the chuck. The lathe “speed” and “feed” charts are

affixed to the front of the headstock to allow the operator to make the proper feed and speed

selections based on the easy to read style of the charts and the well identified gear change levers

as seen in Figure 6 .

The lathe is equipped with a foot brake bar that is located near the lather operators feet and the

operator need only step on the bar to stop the spindle from turning.





Figure 6 – Speed and Feed Charts and Gear Change Levers

The tailstock ( Figure 7 ) is used to support the work piece when used in conjunction with a “live”

or “dead” center and as a holder/support for tapered shank drill bits and drill chucks that enable

drilling of holes in the work piece.






The tailstock is moveable the length of the ways and when locked down the quill can be

extended out of the tailstock by turning the handwheel in a clockwise (CW) direction to contact

the work piece with whatever tool is inserted in the quills Morse Taper at the time.

Tools are removed from the tailstock by turning the handwheel in a counter clockwise (CCW)

thereby retracting the quill into the tailstock and pushing the tool out when it reaches the stop

inside the tailstock.

The bed of the lathe is constructed of cast Meehanite (type of cast iron and process) for stability

during normal machine use. The ways, which are an integral part of the bed casting, support the

carriage and tailstock and are precision ground for accuracy in movement when conducting

machining operations with the lathe.





The lathe is equipped with an aftermarket Digital Readout (DRO) ( Figure 8 ) that displays the

movement of the cross slide (cross feed) and carriage (longitudinal feed). The readout for “X” is

the cross slide and “Z” is for the carriage movement. The DRO is very versatile in that in cantrack tool movement (material removed or tool position) as well as material remaining to be

removed either in a straight line or as a function of diametrical sizing.






1.2.1 Equipment Data

Lathe Manufacturer Sharp Industries Inc.

Model 1764TCapacity 26-inches at the Gap Bed

17-inches over bed (ways)

8-½-inches over the Cross Slide

Spindle Speeds (12) 25, 45, 65, 90, 185, 265, 385, 645,

960, 1385, 2000 and 2105 RPM

Spindle Bore 2-1/16 inches

Spindle Bore Taper No.6 Morse Taper

Spindle Nose (Chuck Attachment) D1-6 Camlock

Tailstock Taper No.4 Morse Taper

Distance Between Centers 64-inches

Number of Feed Changes 48

Feed Selections (Turning) 0.0025 to .01442 inches per revolution (IPR)

Inch Thread Selections (49) 1 to 56 Threads Per Inch (TPI)

Metric Thread Selections (48) 0.5 to 28mm (Millimeters)

D.P. Thread Selections (48) 0.125 to 7mm (Millimeters)Lead Screw Threads 4 TPI

Cross Slide Travel 9-13/16-inches

Compound Rest Travel 6-½ -inches

Quill Travel (Tailstock) 6-5/16-inches

Quill Diameter 2-9/16-inches

Bed Length 100-inches

Bed Width 13-inches

Spindle Motor 7-½ HP, 220/440 Volt, 3-Phase

Digital Readout (DRO) Acu-Rite, TurnMate





1.3 Equipment Connections and Interface

The Manual Lathe does not directly connect to, or interface with, any other plant equipment.

Electrical power to the Manual Lathe is controlled by hand operated ON and OFF rotational

switch located on the power panel as seen in Figure 9 . The power panel also houses controls for

the coolant system, a spindle “jog” button and an emergency “STOP” button.

The Manual Lathe is hard wired into the plant electrical system and is equipped with a set of

three (3) breakers to enable isolation of the lathe for maintenance and/or repairs.

Figure 9 – Power Panel





2.0 Equipment Major Parts

Chapter Objectives:

Describe how the equipment parts perform their function:1. Draw from memory a diagram of the equipment showing major parts

2. State from memory, the names and functions of the major parts

3. Describe the location of the major parts

The major parts of the Manual Lathe are as follows:

1. Lathe Bed and Ways

2. Headstock

3. Speed Gears

4. Feed Gears

5. Carriage

6. Cross Slide

7. Compound

8. Thread Chasing Dial, (1/2 Nut)

9. Tailstock

10. Coolant System11. Digital Readout (DRO)

2.1 Lathe Bed and Ways

As mentioned earlier the lathes bed and ways ( Figure 10 ) are constructed of Meehanite cast iron.

The bed is engineered and constructed in such a way as to give the best rigidity for the machining

operations that the lathe will be subject to during normal operations.

Meehanite is actually two (2) things. First, it’s a patented process for casting metals to exact and

well-defined engineering specifications. Second, it’s a series of superior engineering cast irons

including nodular graphite irons, flake graphite irons and white cast irons.





The dense, fine grain structure of Meehanite metal which assures casting solidity and consistent

physical properties relate the carbide stability of the molten metal, both before and after

processing to the casting section.

Figure 10 – Lathe Bed and Ways

The bed and ways support the remainder of the lathes parts and hold the machines machining

accuracy to tight tolerances over extended periods of time so long as the lathe has been properly

setup or installed on its foundation.

The “ways” of the lathe are an integral part of the lathe bed and are precision ground to exacting

tolerances to allow for the precision machining of a work piece in the longitudinal direction

(using the carriage feed). The ways also locate the tailstocks centerline in line with the

headstocks centerline throughout the tailstocks travel on the ways.

2.2 Headstock

The headstock ( Figure 11 ) houses the spindle along with its support bearings, spindle speed

gears as well as turning and threading feed gears. The lathes chuck (work piece mountingdevice) is attached to the spindle by way of six (6) cam lock pins. The headstock spindle is belt

driven from the drive motor and through the spindle speed gears ( Figure 12 ).





Lathe Chuck

Oil FlowSight Glass


Figure 12 – Spindle/Gear Drive Arrangement





The headstock is equipped with an oil flow sight glass as seen in Figure 11 and also an oil level

sight glass located just below the drive belt access door on the end of the headstock where the oil

level should be maintained at the center of the glass. When the machine (motor) is running thereshould be a steady stream of oil showing in the oil flow sight glass. The headstock is lubricated

with Dextron D.T.E. 26 hydraulic oil.

2.3 Speed Change Gears (Spindle RPM)

The different spindle speeds are selected by turning the spindle speed selector to the desired

position and moving the speed selector lever to the High, Medium or Low range as needed for

the desired spindle RPM ( Figure 13 ).

Speed (RPM)Selection Dial

Speed RangeLever

Figure 13 – Spindle Speed Selection





Shifting of spindle speed gears should be done with the spindle stopped and either manually turning

the chuck by hand or using the control panel “JOG” button while moving the speed dial and/or

speed range (high, medium and low) lever.

Efforts to change speeds with the spindle in motion can result in catastrophic damage to the spindle

speed gears or at the very least, chipped or otherwise damaged gear teeth that may transmit the

imperfection into the machining surfaces of the work piece during normal machining operations.

2.4 Feed and Thread Pitch Change Gears

The lathe is equipped with 48 different rates of feed selections for turning, facing and boring

operations. By placing the gear selection levers in a certain configuration or position the operator

can change the rate at which the carriage or cross slide will move with each revolution of the spindle

based on the feed charts located on the headstock.

A-B Lever

E-F-G Lever

P-L-KJH Lever

Feed Dial

C-D Lever

Figure 14 – Feed and Thread Change Levers





For turning, facing and boring operations the C-D Lever is always in the “D” position and the “C”

position is used only for cutting Metric or Module threads. The A-B Lever selects heavy or light

feeds when performing turning, facing or boring operations while it selects coarse or fine threadsduring threading operations with “A” equaling heavy or coarse and “B” equaling light or fine.

The feed rate for “longitudinal” (carriage) feeds is different from those in the cross feed (cross slide)

direction. The finest longitudinal feed is 0.002 (two-thousandths of an inch) per spindle revolution

while the finest cross feed is 0.0005 (½ thousandth of an inch) per spindle revolution. The different

feed rates are a result of the final gearing in the carriage apron and are necessary because the surface

speed of the work piece decreases as the tool is fed towards the center of the material.

Longitudinal (Carriage) Feed – Table 1

Lever

Position 1 2 3 4 5 6 7 8

ADEH 0.1122 0.0998 0.0838 0.0816 0.0781 0.0748 0.0690 0.0641

ADFH 0.0561 0.0499 0.0445 0.0408 0.0390 0.0374 0.0345 0.0320

ADGH 0.0280 0.0249 0.0224 0.0204 0.0195 0.0187 0.0172 0.0160

BDEH 0.0140 0.0124 0.0112 0.0102 0.0097 0.0093 0.0086 0.0080

BDFH 0.0070 0.0062 0.0056 0.0051 0.0048 0.0046 0.0043 0.0040

BDGH 0.0035 0.0031 0.0028 0.0025 0.0024 0.0023 0.0021 0.0020

The feed selections for the carriage (longitudinal) feed are shown in the chart above and reflect

the different positions of the feed levers and feed dial. You will notice that the P-L-KJH lever is

always in the “KJH” or “H” position when turning, facing or boring a work piece. This is

reflective of the fact that the “K and “J” positions are for threading only with the designation “K”having only one (1) thread pitch (threads per inch) selection of 19-threads per inch when

machining “English” threads





For each 4-letter “lever” combination there are eight (8) possible feed dial selections with No. 1

being the largest incremental feed amount (per revolution) per combination/position.

The cross feed final gear (located in the carriage apron) reduces the feed rate for the cross slide

to those feeds shown in the cross feed chart below.

Cross Slide Feed – Table 2

Lever

Position 1 2 3 4 5 6 7 8

ADEH 0.0300 0.0250 0.0240 0.0210 0.0200 0.0190 0.0176 0.0160

ADFH 0.0150 0.0128 0.0120 0.0104 0.0100 0.0096 0.0088 0.0080

ADGH 0.0072 0.0064 0.0056 0.0052 0.0050 0.0048 0.0044 0.0040

BDEH 0.0036 0.0032 0.0028 0.0026 0.0025 0.0024 0.0022 0.0020

BDFH 0.0018 0.0016 0.0014 0.0013 0.0012 0.0012 0.0011 0.0010

BDGH 0.0009 0.0008 0.0007 0.0006 0.0006 0.0006 0.0005 0.0005

Under normal operating conditions, once the feed rate for the carriage is selected the corresponding

feed rate for the cross slide (cross feed) is used without having to change the cross feed rate or

changing the gears. Under some circumstances the cross feed rate (per revolution amount of feed)

will need to be changed based on a current machining condition or work piece surface finish

requirement (face finish).

Unless otherwise noted on a particular machining drawing/print (legend box) a 125-rms surface is a

standard surface finish for a machined part. A 125-rms finish will have tool marks in the work

piece surface and is most noticeable in a part that has been machined on a mill.

Threading is also accomplished by changing gears for the different threads per inch (TPI) or thread

pitch. Looking at the following English Threads Per Inch Chart one can see the that except for 19-

threads per inch, the P-L-KJH lever is always in the “L” position. For the coarser threads (from 1-7





threads per inch) the A-B lever is in the “A” position and for the finer threads (8-56 threads per

inch) it is in the “B” position with the lever being in the “KJH” or “K” position for 19-threads per

inch.

English Threads (Threads Per Inch) – Table 3

Lever

Position 1 2 3 4 5 6 7 8

ADEL 1 1 1/8 1 ¼ 1 3/8 1 7/16 1 ½ 1 5/8 1 ¾

ADFL 2 2 ¼ 2 ½ 2 ¾ 2 7/8 3 3 ¼ 3 ½

ADGL 4 4 ½ 5 5 ½ 5 ¾ 6 6 ½ 7

BDEL 8 9 10 11 11 ½ 12 13 14

BDFL 16 18 20 22 23 24 26 28

BDGL 32 36 40 44 46 48 52 56

BDFK 19

Metric Threads (Millimeters – MM) – Table 4

Lever

Position 1 2 3 4 5 6 7 8

ACEL 16 18 20 22 23 24 26 28

ACFL 8 9 10 11 11.5 12 13 14

ACGL 4 4.5 5 5.5 5.75 6 6.5 7

BCEL 2 2.25 2.5 2.75 2.875 3 3.25 3.5BCFL 1 1.125 1.25 1.375 1.437 1.5 1.625 1.75

BCGL 0.5 0.562 0.625 0.687 0.718 0.750 0.812 0.875





Metric Threads (Millimeters – MM) – Table 5

Lever

Position 1 2 3 4 5 6 7 8ACEJ 12.8 14.4 16 17.6 18.4 19.2 20.8 22.4

ACFJ 6.4 7.2 8 8.8 9.2 9.6 10.4 11.2

ACGJ 3.2 3.6 4 4.4 4.6 4.8 5.2 5.6

BCEJ 1.6 1.8 2 2.2 2.3 2.4 2.5 2.8

BCFJ 0.8 0.9 1 1.1 1.15 1.2 1.3 1.4

BCGJ 0.4 0.45 0.5 0.55 0.575 0.6 0.65 0.7

Module Threads (Screw Threads) – Table 6

Lever

Position 1 2 3 4 5 6 7 8

ACEP 4 4.5 5 5.5 5.75 6 6.5 7

ACFP 2 2.25 2.5 2.75 2.875 3 3.25 3.5

ACGP 1 1.125 1.25 1.375 1.437 1.5 1.625 1.75

BCEP 0.5 0.56 0.624 0.688 0.718 0.750 0.812 0.875

BCFP 0.26 0.28 0.312 0.344 0.359 0.375 0.408 0.437

BCGP 0.125 0.14 0.156 0.172 0.179 0.187 0.203 0.218

Metric and Module threads (gear) selections are shown in the three (3) charts above. Some of the

metric thread selections are possible (duplicated) with the levers in different positions. For an

example 2-mm threads are possible with lever selection “BCEL-1” and “BCEJ-3.”

Turning is accomplished through the use of drive bars or rods from the headstock gearbox to the

apron gearbox ( Figure 15 ) while threading is accomplished through the use of the “lead screw”

from the headstock to the carriage thread chasing dial ( Figure 16 ).





Feed Drive Bars

Figure 15 Carriage Feed Drive Bars

Threading Lead Screw Threading Chasing Dial

Figure 16 – Threading Lead Screw and Chasing Dial





Turning and boring (carriage movement) is accomplished by pushing the Feed Selection Push-

Pull Knob “in” and pushing “down” on the Feed Engagement Lever. Facing (cross slide

movement) is accomplished by pulling the Feed Selection Push-Pull Knob “out” and pushing“down” on the Feed Engagement Lever ( Figure 17 ). Pulling “up” on the Feed Engagement

Lever in either instance will disengage the feed.

Feed Selection Push-Pull Knob

Thread Chasing Dial

Threading Engagement Lever

Feed Engagement Lever

Figure 17 – Feed Selection Arrangement

Threading (carriage movement only) is accomplished by pushing “down” on the Threading

Engagement Lever at the appropriate time to engage the lead screw nut. The Thread Chasing

Dial indicates the proper time to engage the threading nut with the lead screw ( Figure 17 ).

The thread chasing dial is equipped with a worm gear that engages with the lead screw, which

causes the dial to rotate when the lead screw is turning.





Lead Screw

Worm Gear

Thread Dial

Figure 18 – Thread Chasing Mechanism

2.5 Carriage

The carriage assembly mounts directly on the lathe ways and provides longitudinal travel for

turning and boring operations as well as threading. It also provides a working platform for the

cross slide and compound rest as well as support for the final feed and threading gears located

within the apron (front portion of the carriage facing the operator).

The carriage apron serves as a lube oil reservoir that lubricates the apron gears by way of a

splash system and lubricates the lathe ways through the use of a one shot spring return piston

pump as seen in Figure 19 .





Oil Level Sight Glass

One Shot Oil Pump

Figure 19 – Oil Pump and Oil Sight Glass

Oiling of the ways is accomplished by pulling out on the oil pump knob and releasing it to allow

the internal return springs to pump oil to the ways with oiling being done once per day. The oil

level in the apron must be maintained in the center of the sight glass to allow for the splash oilingof the apron gears and must be replenished (filled) as oiling of the ways takes oil from the apron

reservoir each time the ways are oiled. Dextron D.T.E.-27 is used as the lubricant.

Also located on the carriage/apron are the manual carriage travel and cross slide handwheels as

well as the automatic feed and threading engagement levers as described in the previous Section

2.4 .

The apron is equipped with two (2) push-pull knobs that control selection of the feed axis

[longitudinal (carriage) or cross (cross slide)] as well as the direction of feed (forward or reverse

on the carriage and in or out on the cross slide). Forward on the carriage would be towards the

headstock with reverse being away from the headstock ( Figure 20 ).





Spindle Start, Stopand Reverse Lever

Manual Cross Slide

Manual Carriage

Carriage/Cross

Forward/Reverse

Figure 20 – Carriage and Cross Slide Controls

A spindle start, stop and reverse lever is located on the right side of the carriage apron ( Figure

20 ). Pulling the lever up will turn the spindle forward (counter clockwise looking at the chuck)

and pushing the lever down will cause the spindle to turn in a reverse (clockwise) direction. Stop

is located in the middle of the upper and lower travel.

The carriage feed is equipped with a feed stop lever and adjustable position feed stops ( Figure

21 ).

Figure 12 – Adjustable Position Feed Stops





The stops can be moved along their mounting rod and set in any desired position to correspond

to a stop machining point on the work piece. When the carriage is in automatic feed (forward or

reverse) the feed will be stopped when the feed stop lever ( Figure 22 ) engages one of the feedstop devices.

Feed Stop Lever

Figure 22 – Carriage Feed Stop Lever

2.6 Cross Slide

The cross slide is used for manual positioning (along with manual movement of the carriage) of a

tool in the tool holder for any machining operation and it may also be used for manual facing of

a work piece.

The cross slide is also used in automatic feed facing of a work piece and/or when used in

conjunction with a taper attachment. Manual use of the cross slide is accomplished by turning

the manual handwheel either clockwise, which moves the cross slide “in” towards the work piece







The compound rest is so named because it is upon the compound that the cutting tool holder and

thus the cutting tool rest. The compound can be used to machine and angle or taper in a work

piece or set a single point threading tool up at the right feed angle (29 degrees) for threading awork piece by advancing the compound and thus the cutting tool after each tool pass until the

required thread depth and/or thread classification fit are achieved.

A tool holder or other peripheral device is mounted to the compound by way of a “T” slot in the

compound located at the uppermost and forward section of the compound as can be seen in

Figure 23 on the preceding page.

Any machining done using the sliding motion of the compound only is strictly “manual” as there

are no provisions for automatic feeding of the compound on this lathe.

2.8 Thread Chasing Dial

The thread chasing dial ( Figure 24 ) allows the operator to choose the starting point of a threading

operation. The dial consists of numbered graduated marks that indicate the correct time to engage

the threading gear based on the desired thread pitch (threads per inch or threads per millimeter).

1

2

3

4

Figure 24 – Thread Chasing Dial





The thread chasing dial works off the lead screw and is used as a tracking device. The dial tells

the operator when to engage the half nut lever so the tool follows the same thread groove every

time. The lathes machining feed selection (turning, boring and facing) must be in “neutral”when cutting threads with only the lead screw turning and NOT the feed drive bars.

The proper engagement point or line on the dial depends on the number of threads per inch or per

millimeter that is required. Generally speaking, once the correct starting point is selected

(numbered line or otherwise) the safest bet is to use the same starting point (line) for each

successive pass to prevent starting in the middle of a thread high point and destroying the

threads.

The thread chasing dial will turn when the lead screw is turning or when the carriage is moved

forward or reverse when turning or boring operations are being performed on a work piece. In

other words, the thread dial worm gear is in mesh or contact with the lead screw at all times and

is only useful (used) when actually threading a work piece with the turning, boring and facing

feed in neutral.

2.9 Tailstock and Steady RestThe lathes tailstock ( Figure 25 ) has multi purposes. With the use of a live or dead center it can

be used to support the work piece by way of a centering hole that has been drilled in the end of

the work piece.

The tailstock can also be used to drill a hole in the end of a work piece that is gripped by the

chuck. Depending on the length of the work piece it may need to be supported by a steady rest

(Figure 26 ) in order to facilitate the drilling of a centering hole, which would then allow the

work piece to be supported by a live, or dead center. The steady rest could then be removed to

enable turning of the outside diameter of a work piece.





Quill Feed Handwheel

Quill Cam Lock


Steady Rest

Figure 26 – Steady Rest





The work piece should have a machined, round surface where it sits in the steady rest to enable

the drilling of a hole in the end of the work piece.

Both the Tailstock and the Steady Rest are clamped in place on the lathe ways when they are in

use.

The tailstock is equipped with a quill that has a No.4 Morse Taper to accept drill bits, drill

chucks and other devices for machining and/or drill different configurations in the end of the

work piece as well as live or dead centers for supporting the work piece.

The tailstock is locked in place on the ways with a hold down clap that is tightened with the

applicable (supplied) wrench. The quill is advanced or retracted within the tailstock by turning

the handwheel located at the end of the tailstock. The handwheel is equipped with a graduated

dial to facilitate drill depth of a hole in a work piece as well as a graduated scale on the quill

itself.

When being used in conjunction with a live or dead center, the quill is locked in place by the

quill cam lock once the desired pressure on, or position of the center to the work piece isestablished.

2.10 Coolant System

The lathe is equipped with a coolant system with a flexible nozzle arrangement to direct coolant

to the work piece at the point of tool contact when machining ( Figure 27 ). The system is

controlled from the power panel and has a rotating On/Off switch as well as an “in service”

indicating light ( Figure 28 ).

The coolant is a mixture of soluble oil and water at a mixture rate of approximately 1:20 [one (1)

part soluble oil to 20 parts water]. The coolant should be changed periodically at four (4) to six

(6) week intervals to prevent bacteria buildup in the system.





Flexible Coolant Feed Line

Figure 27 – Coolant Feed Line

Coolant Controls and Indication

Figure 28 – Coolant Controls





2.11 Digital Readout (DRO)

The lathe is equipped with a digital readout (DRO) that gives the operator the exact coordinates of

the tool with respect to the work piece or some defining position on the work piece at all times(Figure 29 ).


Manufactured by ACU-RITE, the TurnMate digital readout allows the operator to calculate or know

the exact position of the cutting tool in relation to the work piece during machining operations. The

readout can be used to track movement of both the cross slide (cross X-axis) and the carriage

(longitudinal Z-axis) or to set machining end points to a certain dimensional readout on the desired

axis.

The end point could be calculated and set at 0.000 or any point of measurable distance on the axis

(cross or longitudinal) as read on the axis readout.





At any point along the travel of either the carriage or the cross slide, the DRO can be zeroed out

(0.000) to allow for a “next step” measurement or datum point for then moving the carriage or cross

slide in either direction and allowing the operator to come back to the zero point at any time byreversing travel direction of the selected axis or device (carriage or cross slide).

Detailed instructions for setting the different parameters of each axis are covered in the operations

manual for the DRO.





3.0 Equipment Preventive and Corrective Maintenance

3.1 Preventive MaintenancePreventive maintenance for the Manual Lathe consists of maintaining the oil level in the

headstock and carriage apron along with daily “one shot” oiling of the machine ways.

Periodic emptying of the chip pan (as needed or full) and changing of the coolant/cutting fluid in

the reservoir is done on a four (4) to six (6) week frequency.

3.2 Corrective Maintenance

Corrective maintenance is performed on the lathe on an as needed basis by qualified personnel

either by a vendor or in house machinist.





4.0 References

Sharp Model 1764T Operation and Service Manual



Industrial Resources, Inc. Manual LatheMachine Shop IRI-MS01-EMP


MANUAL LATHE

TRAINING EQUIPMENT MAINTENANCE PROCEDURE (IRI-MS01–EMP)



September 2, 2004

©This document is the property of Industrial Resources, Inc. Copies and distribution of this document is prohibitedunless written authorization is granted by Industrial Resources, Inc.





PREFACE

This Training Equipment Maintenance Training Procedure (EMP) has been designed to assist you

in meeting the requirements of Module IRI-MS01 of the Machine Shop Training Program. It

contains information pertaining to maintenance of the Manual Lathe. This includes purpose,

precautions, limits and setpoints, procedures and references for maintaining equipment.

You should also inspect the equipment, identifying its components and controls. Should you have

additional question about the equipment maintenance, ask your supervisor.





MANUAL LATHE

TRAINING EQUIPMENT MAINTENANCE PROCEDURE

TABLE OF CONTENTS

I. Purpose................................................................................................................................ 0

II. Precautions, Limitations, and Setpoints.............................................................................. 0

III. Procedure ............................................................................................................................ 1

A. Operating Procedure ..................................................................................................... 1

B. Preventive Maintenance................................................................................................ 5

C. Corrective Maintenance ................................................................................................ 5



I. Purpose

This procedure provides information and guidance for the correct and safe use and

maintenance of the Manual Lathe.

II. Precautions, Limitations, and Setpoints

A. Prior to performing any work with the Manual Lathe, clear the work area of clutter

and ensure adequate lighting exists to perform the desired work.

B. Ensure the spindle start lever on the carriage is in the neutral position prior to

turning the power on to the lathe.

C. Do NOT wear loose clothing when operating the lathe.

D. Ensure there is an adequate amount of cutting fluid in the reservoir.

E. Never leave the chuck wrench in the chuck when not actually in use.

F. Ensure the proper use of safety equipment such as safety glasses when operating

the lathe.

G. Ensure that all guards are in place prior to starting the machine.

H. Oil the lathes ways at the start of each day’s first use of the lathe.

I. Isolate electrical power prior to performing any maintenance work on the lathe.





III. Procedure

The following procedures provide detailed instructions for conducting routineoperation, preventive and corrective maintenance on the Manual Lathe.

A. Operating Procedure

The following steps are to be used by the equipment operator when using the Manual

Lathe to machine a work piece.

__1. Check that the machines chip pan and ways are clear of any debris or

previously used material.

__2. Make sure that the proper lubrication oil to all moving parts have been

completed and that the reservoirs are filled (headstock and carriage apron).

__3. Make sure that the spindle control lever at the apron is in the neutral

position.

__4. Turn the power on to the lathe by turning the ON/OFF switch to the “ON”

position and observing that the “ON” indicating light is illuminated.

__5. If needed, turn the coolant pump on by turning the ON/OFF switch to the

“ON” position and observe that the “ON” indicating light is illuminated.

__6. To start the spindle turning forward (counter clockwise) pull up on the

spindle control lever located on the right side of the carriage apron.





__7. To stop the spindle, move the spindle control lever to the “neutral”

position by pushing it down from the “forward” position and step on the

foot brake bar/pedal. __8. To start the spindle in reverse (clockwise), pull the spindle lever out (to

the right away from the carriage) and push it down.

__9. For an emergency “STOP” step on the foot brake bar/pedal or depress the

Emergency “STOP” button on the power panel.

__10. Select the desire spindle speed by choosing Low, Medium or High range

with the associated lever, using the spindle “Jog” button if necessary.

__11. Select the desired RPM by turning the speed selection dial (use the spindle

“Jog” button if necessary).

NOTE: DO NOT CHANGE SPEEDS WITH THE SPINDLE IN FULL

MOTION

NOTE: DO NOT SHIFT THE COARSE-FINE LEVER IF THE

SPINDLE IS TURNING OVER 385 RPM.

Feed and Thread Selection

__1. Using the feed and/or thread charts, select the desired feed rate or thread

pitch.

__2. Make sure the carriage “spindle control lever” is in the “neutral” position

and the spindle is NOT turning.





__3. Move the gear change levers to the desired configuration for the selected

feed/thread pitch.

__4. Do NOT force the change levers when engaging into the selected

position(s). (Use the gear turning knob located under the headstock back

cover to help mesh the gears.)

Turning, Boring and Facing Operations

__1. Place the work piece in the chuck and indicate in a necessary.

__2. Start the spindle turning by pulling up on the spindle control lever.

__3. Using the manual carriage and cross slide handwheels, locate the cutting

tool at the work piece for the first machining pass.

__4. For longitudinal machining (turning or boring) push in on the feed axis

push-pull knob and for cross slide machining (facing) pull out on theknob.

__5. For “forward” longitudinal (towards the headstock) or cross slide feed

(away from the operator), push the forward/reverse push-pull knob in, and

for reverse feed, pull the knob out.

__6. Ensure the cutting tool elevation is aligned with the centerline of the work

piece.





__7. Using the manual feed handwheels (carriage and cross slide) traverse the

work piece the desired length or distance of required machining with the

spindle stopped.

__8. Set the feed stops at the end(s) of travel if so desired.

__9. Make adjustments in the tooling setup as necessary to complete the

machining operation using the automatic feed(s).

__10. Move the carriage and/or cross slide as necessary to bring the tool to its

start position.

__11. Start the spindle turning in the desired direction by pulling up or pushing

down on the spindle control lever.

__12. Engage the carriage or cross slide feed by pushing down on the feed

engagement lever located on the front of the carriage apron.

__13. If feed stops are used, ensure that they engage the feed stop lever at the

appropriate time or manually stop the feed at the desired point.

__14. Continue the machining operation until such time as the desired dimension

and/or profile of the work piece is accomplished.

__15. Remove the work piece from the chuck by loosening the chuck jaws.

__16. Using a paint brush or similar item, clear the lathe ways, cross slide and

carriage of all machining debris (chips) and clean out the chip pan as

needed.





__17. Turn the lathe off by turning the ON/OFF switch to the “OFF” position

and turn the coolant system “OFF” in the same manner.

B. Preventive Maintenance

The following steps are to be used by the equipment operator when performing

preventive maintenance on the Manual Lathe.

Cleaning and Lubrication

__1. Clean the chip pan as needed.

__2. Clear machining chips from the lathes horizontal surfaces after each use.

__3. Check the level of the cutting fluid reservoir and add as needed.

__4. Lubricate the bed ways daily (as used) with light machine oil.

__5. Check the oil level in the headstock periodically and add D.T.E. 26 oil as

needed.

__6. Check the apron oil level daily and add D.T.E. 27 oil as needed.

__7. Every 4 to 6 weeks, drain and refill the coolant reservoir with fresh

coolant/cutting fluid.

C. Corrective Maintenance

Corrective maintenance is performed on the lathe on an as needed basis by qualified

personnel either by a vendor or in house machinist.



MANUAL LATHE

TRAINING EQUIPMENT MAINTENANCE

JOB PERFORMANCE MEASURE (IRI-MS01–JPM)





Industrial Resources, Inc. Manual LatheMachine Shop IRI-MS01-JPM

Performance Measure: Manual Lathe

Name: __________________________________

All Parts Satisfactorily Completed:

________________________________________ ____________________(Supervisor’s Signature) (Date)

Supervisor’s Comments: __________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

References:• Training Module IRI-MS01

Materials Needed:• Pencil and Clipboard• Equipment Maintenance Description – Manual Lathe (IRI-MS01-EMD)• Equipment Maintenance Procedure – Manual Lathe (IRI-MS01-EMP)• Associated Maintenance Checklist, Charts, Parts List, Technical Manuals

Safety/Environmental:• Wear hard hats, safety glasses, safety toe shoe, and ear plugs as required.• Discuss environmental hazards associated with performing maintenance of the equipment.• Discuss any safety precaution that must be observed while performing the procedure.

Note: Always observe all plant safety rules in accordance with Safety and Health Procedures and all

Federal, State and/or Local TOSHA Standards.





Part A: Locate Equipment

Locate and identify the following equipment and major components.

1. Manual Lathe2. Headstock3. Carriage4. Cross Slide5. Compound Rest6. Tailstock7. Chuck8. Steady Rest

Satisfactorily Completed ____________________________

Part B: Controls/Breakers

Locate and identify the following isolation devices.1. Breakers2. Lathe ON-OFF Switches

Satisfactorily Completed _________________________





Part C: Preparation for Maintenance

This is to be performed under direction of the Shop Supervisor.

Demonstrate the following preparation for use of the Manual Lathe including:1. Prior to performing any work with the Manual Lathe, clear the work area of clutter and

ensure adequate lighting exists to perform the desired work.2. Ensure the spindle start lever on the carriage is in the neutral position prior to turning the

power on to the lathe.3. Do NOT wear loose clothing when operating the lathe.4. Ensure there is an adequate amount of cutting fluid in the reservoir.5. Never leave the chuck wrench in the chuck when not actually in use.6. Ensure the proper use of safety equipment such as safety glasses when operating the lathe.

7.

Ensure that all guards are in place prior to starting the machine.8. Oil the lathes ways at the start of each day’s first use of the lathe.9. Isolate electrical power prior to performing any maintenance work on the lathe.

Satisfactorily Completed __________________________

Part D: Operating Procedure


Demonstrate the following operational steps for the safe and efficient operation of the ManualLathe.1. Check that the machines chip pan and ways are clear of any debris or previously used

material.2. Make sure that the proper lubrication oil to all moving parts have been completed and that

the reservoirs are filled (headstock and carriage apron).3. Make sure that the spindle control lever at the apron is in the neutral position.4. Turn the power on to the lathe by turning the ON/OFF switch to the “ON” position and

observing that the “ON” indicating light is illuminated.

5.

If needed, turn the coolant pump on by turning the ON/OFF switch to the “ON” positionand observe that the “ON” indicating light is illuminated.6. To start the spindle turning forward (counter clockwise) pull up on the spindle control

lever located on the right side of the carriage apron.(Continued)





Part D: Operating Procedure (Continued)

7.

To stop the spindle, move the spindle control lever to the “neutral” position by pushing itdown from the “forward” position and step on the foot brake bar/pedal.8. To start the spindle in reverse (clockwise), pull the spindle lever out (to the right away

from the carriage) and push it down.9. For an emergency “STOP” step on the foot brake bar/pedal or depress the Emergency

“STOP” button on the power panel.10. Select the desire spindle speed by choosing Low, Medium or High range with the

associated lever, using the spindle “Jog” button if necessary.11. Select the desired RPM by turning the speed selection dial (use the spindle “Jog” button if

necessary).

Feed and Thread Selection1. Using the feed and/or thread charts, select the desired feed rate or thread pitch.2. Make sure the carriage “spindle control lever” is in the “neutral” position and the spindle is

NOT turning.3. Move the gear change levers to the desired configuration for the selected feed/thread pitch.4. Do NOT force the change levers when engaging into the selected position(s). (Use the

gear turning knob located under the headstock back cover to help mesh the gears.)

Turning Boring and Facing Operations

1. Place the work piece in the chuck and indicate in a necessary.

2.

Start the spindle turning by pulling up on the spindle control lever.3. Using the manual carriage and cross slide handwheels, locate the cutting tool at the work piece for the first machining pass.

4. For longitudinal machining (turning or boring) push in on the feed axis push-pull knob andfor cross slide machining (facing) pull out on the knob.

5. For “forward” longitudinal (towards the headstock) or cross slide feed (away from theoperator), push the forward/reverse push-pull knob in, and for reverse feed, pull the knobout.

6. Ensure the cutting tool elevation is aligned with the centerline of the work piece.7. Using the manual feed handwheels (carriage and cross slide) traverse the work piece the

desired length or distance of required machining with the spindle stopped.8. Set the feed stops at the end(s) of travel if so desired.9. Make adjustments in the tooling setup as necessary to complete the machining operation

using the automatic feed(s).10. Move the carriage and/or cross slide as necessary to bring the tool to its start position.11. Start the spindle turning in the desired direction by pulling up or pushing down on the

spindle control lever.(Continued)





Part D: Operating Procedure (Continued)

12.

Engage the carriage or cross slide feed by pushing down on the feed engagement leverlocated on the front of the carriage apron.13. If feed stops are used, ensure that they engage the feed stop lever at the appropriate time or

manually stop the feed at the desired point.14. Continue the machining operation until such time as the desired dimension and/or profile

of the work piece is accomplished.15. Remove the work piece from the chuck by loosening the chuck jaws.16. Using a paint brush or similar item, clear the lathe ways, cross slide and carriage of all

machining debris (chips) and clean out the chip pan as needed.17. Turn the lathe off by turning the ON/OFF switch to the “OFF” position and turn the

coolant system “OFF” in the same manner.


Part E: Preventive Maintenance


Demonstrate the steps on the Manual Lathe required to perform the following preventive

maintenance tasks.

Cleaning and Lubrication1. Clean the chip pan as needed.2. Clear machining chips from the lathes horizontal surfaces after each use.3. Check the level of the cutting fluid reservoir and add as needed.4. Lubricate the bed ways daily (as used) with light machine oil.5. Check the oil level in the headstock periodically and add D.T.E. 26 oil as needed.6. Check the apron oil level daily and add D.T.E. 27 oil as needed.7. Every 4 to 6 weeks, drain and refill the coolant reservoir with fresh coolant/cutting fluid.






Part F: Corrective Maintenance


Demonstrate the steps on the Manual Lathe required to perform the following correctivemaintenance.

1. Corrective maintenance is performed on the lathe on an as needed basis by qualified personneleither by a vendor or in house machinist.


Part G: Personnel and Equipment Safety

Performed all aspects of the JPM using safe operating practices and following plant safety andenvironmental procedures.




MANUAL LATHE

TRAINING EQUIPMENT MAINTENANCE

TEST QUESTIONS (IRI-MS01–Q)








6. (IRI-MS01-Q) The spindle start/stop lever is located on __________.A. the left side of the carriage apronB. the right side of the carriage apronC. the front of the headstockD. the front of the carriage apron

7. (IRI-MS01-Q) The headstock uses D.T.E. ______ oil for lubrication of the internal gears and bearings.A. 26B. 27C. 28D. 29

8. (IRI-MS01-Q) The lathes ways are constructed of ___________.A. hardened and ground tool steelB. gray cast ironC. MeehaniteD. cold rolled boiler plate

9. (IRI-MS01-Q) Threading on the lathe is accomplished by engaging the thread feed lever at the

appropriate time based on the position of___________.A. the tool bitB. thread dialC. the work pieceD. tailstock

10. (IRI-MS01-Q) Under normal operating conditions, pulling up on the spindle start/stop lever willcause the spindle to ________________________.A. stop turningB. turn in a reverse direction

C. turn in a clockwise directionD. turn is a counter clockwise direction






16. (IRI-MS01-Q) The thread chart for English threads shows that there are _____ possible threadselections.

A. 49B. 48C. 40D. 56

17. (IRI-MS01-Q) The headstock spindle is fitted with a ______ Morse taper.

A. No.3B. No.4C. No.6

D. No.5

18. (IRI-MS01-Q) The feed rate chart shows that there are _______ feed selections.A. 56B. 40C. 49D. 48

19. (IRI-MS01-Q) The maximum swing over the cross slide is ____________.

A. 8-7/8 inchesB. 9-7/8 inchesC. 6-7/8 inchesD. 9-13/16 inches

20. (IRI-MS01-Q) There are _____ spindle speed selections.

A. 16B. 14C. 12D. 10

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