OPTIMUM

MASCHINEN - GERMANY

Operating manual
Version 1.2

Lathe
D330 x 1000
D330 x 1000 DPA

Illustr. 0-1: D330x1000 DPA

© 2009

Keep for future reference!

GB

22 / 09 / 2009 Lathe D 330 x 1000 ; Version 1.2 Page 1

OPTIMUM
MASCHINEN - GERMANY

Table of contents

1 Safety
1.1 Safety warnings (warning notes) ........................................................................................... 7
1.1.1 Classification of hazards ............................................................................................ 7
1.1.2 Further ideograms ..................................................................................................... 8
1.2 Proper use ............................................................................................................................ 8
1.3 Possible dangers caused by the lathe .................................................................................. 9
1.4 Qualification of personnel ...................................................................................................... 9
1.4.1 Target group .............................................................................................................. 9
1.4.2 Authorized persons .................................................................................................. 10
1.4.3 Obligations of the operator ...................................................................................... 10
1.4.4 Obligations of the user ............................................................................................. 10
1.4.5 Additional qualification requirements ....................................................................... 10
1.5 User’s position ..................................................................................................................... 10
1.6 Safety measures during operation ...................................................................................... 11
1.7 Safety devices ..................................................................................................................... 11
1.7.1 Lockable main switch ............................................................................................... 12
1.7.2 EMERGENCY-STOP ............................................................................................... 12
1.7.3 Protective cover with safety switch .......................................................................... 12
1.7.4 Lathe chuck protection with position switch ............................................................. 13
1.7.5 Prohibition, warning and mandatory labels .............................................................. 13
1.8 Safety check ....................................................................................................................... 14
1.9 Personal protective equipment ............................................................................................ 15
1.10 Safety during operation ....................................................................................................... 15
1.11 Safety during maintenance ................................................................................................. 16
1.11.1 Switching-off and securing the lathe ........................................................................ 16
1.11.2 Use of lifting equipment ........................................................................................... 16
1.11.3 Mechanical maintenance work ................................................................................ 16
1.12 Accident report .................................................................................................................... 17
1.13 Electrical system ................................................................................................................. 17
2 Technical Data
2.1 power connection ................................................................................................................ 18
2.2 Machine data ...................................................................................................................... 18
2.7 Emissions ............................................................................................................................ 19
2.3 dimensions .......................................................................................................................... 19
2.4 working area ........................................................................................................................ 19
2.5 environmental conditions .................................................................................................... 19
2.6 operating material ............................................................................................................... 19
2.8 Dimensions, installation plan D330x1000 ........................................................................... 21
2.9 Dimensions, installation plan D330x1000 DPA ................................................................... 22
3 Assembly
3.1 Delivery volume ................................................................................................................... 23
3.2 Transport ............................................................................................................................. 23
3.3 Storage ............................................................................................................................... 24
3.4 Installation and assembly .................................................................................................... 24
3.4.1 Requirements of the installation site ........................................................................ 24
3.4.2 Load end position .................................................................................................... 25
3.4.3 Installation ................................................................................................................ 26
3.4.4 Anchoring-free assembly ......................................................................................... 26
3.4.5 Anchored assembly ................................................................................................. 27
3.5 First use .............................................................................................................................. 27
3.5.1 Cleaning and greasing ............................................................................................. 27
3.5.2 Visual inspection ...................................................................................................... 27
3.5.3 Functional check ...................................................................................................... 27
3.5.4 Power connection .................................................................................................... 27
3.5.5 Functional test ......................................................................................................... 28
3.5.6 Coolant provision ..................................................................................................... 28
© 2009 GB

3.6 Optional accessories ........................................................................................................... 29

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4 Levelling- damping element SE1 and SE2

4.1 Mounting: ............................................................................................................................. 31
4.2 Max. weight force per element: ........................................................................................... 31
4.3 Dimension SE1/ SE2 ........................................................................................................... 32
5 Operation
5.1 Safety .................................................................................................................................. 33
5.2 Control and indicating elementsBedien- und Anzeigeelemente .......................................... 33
5.2.1 Overview of the control elements ............................................................................. 34
5.2.2 Overview of indicating elements .............................................................................. 35
5.2.3 Control elements ...................................................................................................... 35
5.3 Speed adjustment ............................................................................................................... 36
5.3.1 Turning direction ...................................................................................................... 36
5.4 Feed .................................................................................................................................... 36
5.4.1 Feed direction .......................................................................................................... 37
5.5 Tool holder .......................................................................................................................... 37
5.6 Switching the lathe on ......................................................................................................... 38
5.6.1 Main switch .............................................................................................................. 38
5.7 Head spindle seat ................................................................................................................ 38
5.7.1 Lathe chuck .............................................................................................................. 39
5.7.2 Mounting workpiece holders .................................................................................... 39
5.8 Mounting of rests ................................................................................................................. 40
5.8.1 Follow and steady rests ........................................................................................... 40
5.9 Bed insert ............................................................................................................................ 40
5.10 Feed tables .......................................................................................................................... 41
5.10.1 Metric threads / longitudinal turning ......................................................................... 41
5.10.2 Thread based on inch - system ................................................................................ 43
5.10.3 Modular threads ....................................................................................................... 44
5.10.4 Diametrically threads (trapezoid) ............................................................................. 44
5.10.5 Change of position of the change gear wheels ........................................................ 44
5.10.6 Threading gauge ...................................................................................................... 45
5.11 Tailstock .............................................................................................................................. 46
5.11.1 Cross-adjustment of the tailstock ............................................................................. 46
5.12 General working notes ........................................................................................................ 47
5.12.1 Streight turning ......................................................................................................... 47
5.12.2 Facing and recesses ................................................................................................ 47
5.12.3 Fixing the lathe saddle ............................................................................................. 47
5.12.4 Turning between centres ......................................................................................... 48
5.12.5 Turning short tapers with the top slide ..................................................................... 48
5.12.6 Thread-cutting .......................................................................................................... 49
5.12.7 Coolant ..................................................................................................................... 49
6 Cutting speeds
6.1 Choosing the right cutting speed ......................................................................................... 50
6.2 Influences on the cutting speed ........................................................................................... 50
6.3 Example for the determination of the required rotation speed on your lathe ....................... 50
6.4 Cutting speed table ............................................................................................................. 51
7 Appendix turning
7.1 ISO-designation system for tool holder, inside machining ................................................. 53
7.2 ISO-designation system for tool holder, outside machining .............................................. 54
7.3 Cutter with hard metal reversible carbide tip soldered on ................................................... 55
7.4 Cut the first chips ................................................................................................................. 55
7.5 Outside machining, longitudinal turning and facing ............................................................. 57
7.6 Inside machining, drilling and longitudinal turning ............................................................... 57
7.7 Tapping of external and internal threads ............................................................................. 58
7.7.1 Thread types ............................................................................................................ 59
7.7.2 Metric thread (60° flank angle) ................................................................................. 61
7.7.3 British threads (55° flank angle) ............................................................................... 62
© 2009

7.7.4 Indexable inserts ...................................................................................................... 63

7.7.5 Examples for thread cutting ..................................................................................... 64
GB

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7.8 Recessing, cutting off and turning off .................................................................................. 66

7.9 Turning cones with high precision ....................................................................................... 68
7.10 Cutting material ................................................................................................................... 71
7.10.1 Cutting materials for chipping .................................................................................. 71
7.11 Standard values for cutting data when turning .................................................................... 72
7.11.1 Cutting speed table .................................................................................................. 73
7.12 Grinding or regrinding of cutting edge geometries of turning tools ..................................... 73
7.12.1 Terms for the turning tool ......................................................................................... 74
7.12.2 Cutting edge geometry for turning tools ................................................................... 75
7.12.3 Types of cutting form levels ..................................................................................... 75
7.13 Lifetime and wear characteristics ........................................................................................ 77
8 Maintenance
8.1 Safety .................................................................................................................................. 79
8.1.1 Preparation .............................................................................................................. 79
8.1.2 Restarting ................................................................................................................ 79
8.2 Inspection and maintenance ............................................................................................... 79
8.3 Repair ................................................................................................................................. 85
9 Ersatzteile - Spare parts - D330
9.1 Ersatzteilzeichnung Maschinenbett - Drawing spare parts machine bed ............................ 86
9.2 Ersatzteilzeichnung Maschinenunterbau - Drawing spare parts machine substructure 87
9.3 Ersatzteilzeichnung Antrieb, Spindelbremse, Abdeckungen - Drawing spare parts actua-
tion, spindle break, covers 88
9.4 Ersatzteilzeichnung Steuerung - Drawing spare parts control ............................................ 89
9.5 Ersatzteilliste Maschinenbett, Maschinenunterbau, Antrieb, Spindelbremse, Steuerung - Spa-
re parts list machine bed, Actuation, Spindle break, Control 90
9.6 Ersatzteilzeichnung Getriebe Spindelstock 1-6 - Drawing spare parts headstock gear 1-6 92
9.7 Ersatzteilzeichnung Getriebe Spindelstock 2-6 - Drawing spare parts headstock gear 2-6 93
9.8 Ersatzteilzeichnung Getriebe Spindelstock 3-6 - Drawing spare parts headstock gear 3-6 94
9.9 Ersatzteilzeichnung Getriebe Spindelstock 4-6 - Drawing spare parts headstock gear 4-6 95
9.10 Ersatzteilzeichnung Getriebe Spindelstock 5-6 - Drawing spare parts headstock gear 5-6 96
9.11 Ersatzteilzeichnung Getriebe Spindelstock 6-6 - Drawing spare parts headstock gear 6-6 97
9.12 Ersatzteilliste Spindelstock - Spare parts list headstock ..................................................... 98
9.13 Ersatzteilzeichnung Vorschubgetriebe 1-4 - Drawing spare parts feed gear 1-4 .............. 101
9.14 Ersatzteilzeichnung Vorschubgetriebe 2-4 - Drawing spare parts feed gear 2-4 ... 102
9.15 Ersatzteilzeichnung Vorschubgetriebe 3-4 - Drawing spare parts feed gear 3-4 ... 103
9.16 Ersatzteilzeichnungen Vorschubgetriebe 4-4 - Drawing spare parts feed gear 4-4 ... 104
9.17 Ersatzteilzeichnung Wechselradgetriebe - Drawing spare parts change wheel gear 105
9.18 Ersatzteilzeichnung Schlosskasten 1-3 - Drawing spare parts apron 1-3 ........................ 108
9.19 Ersatzteilzeichnung Schlosskasten 2-3 - Drawing spare parts apron 2-3 ........................ 109
9.20 Ersatzteilzeichnung Schlosskasten 3-3 - Drawing spare parts apron 3-3 ........................ 110
9.21 Ersatzteilzeichnung Schlosskasten, Gewindeuhr - Drawing spare parts apron, threading gau-
ge 111
9.22 Ersatzteilzeichnung Planschlitten - Drawing spare parts compound slide ........................ 114
9.23 Ersatzteilzeichnung Oberschlitten - Drawing spare parts top slide ................................... 115
9.24 Ersatzteilzeichnung Reitstock - Drawing spare parts tailstock .......................................... 118
9.24.1 Ersatzteile Reitstock - Spare parts list tailstock .................................................... 119
9.25 Ersatzteilzeichnung feststehehde Lünette - Drawing spare parts steady rest .................. 120
9.25.1 Ersatzteile Feststehende Lünette - Spare parts steady rest .................................. 121
9.26 Ersatzteilzeichnung mitlaufende Lünette - Drawing spare parts follow rest ...................... 122
9.26.1 Ersatzteile mitlaufende Lünette - Spare parts follow rest ...................................... 122
9.27 Ersatzteilzeichnung Drehfutterschutz - Drawing spare parts chuck protection . 123
9.27.1 Ersatzteile Drehfutterschutz - Spare parts chuck protection .................................. 123
9.28 Ersatzteilzeichnung Spanschutz - Drawing spare parts chip protection
D330x1000 124
9.29 Ersatzteilzeichnung Spanschutz - Drawing spare parts chip protection
D330x1000 DPA 124
9.29.1 Ersatzteile Spanschutz - Spare parts chip protection ............................................ 125
9.30 Ersatzteilzeichnung Maschinenlampe - Drawing spare parts machine lamp .................... 126
9.30.1 Ersatzteile Maschinenlampe - Spare parts machine lamp ..................................... 126
© 2009 GB

9.31 Ersatzteilzeichnung D330x1000 DPA, DPA2000, Messleisten - Spare parts drawing

D330x1000 DPA, DPA2000, measuring gib 127

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MASCHINEN - GERMANY

9.31.1 Ersatzteile DPA2000, Messleisten - Spare parts DPA2000, measuring gib .......... 127
9.32 Schaltplan - Wiring diagram D330x1000 ........................................................................... 128
9.32.1 Ersatzteilliste Elektrik - Spare parts list electrical components D330x1000 ........... 129
9.33 Schaltplan - Wiring diagram D330x1000 Vario ................................................................. 130
9.33.1 Ersatzteilliste Elektrik - Spare parts list electrical components D330x1000 Vario . 131

10 Malfunction
11 Appendix
11.1 Copyright ........................................................................................................................... 134
11.2 Terminology/Glossary ....................................................................................................... 134
11.3 Liability claims for defects / warranty ................................................................................. 135
11.4 Note regarding disposal / options to reuse: ....................................................................... 135
11.4.1 Decommissioning ................................................................................................... 136
11.4.2 Disposal of the packaging of new devices ............................................................. 136
11.4.3 Disposing of the old device .................................................................................... 136
11.4.4 Disposal of electrical and electronic components .................................................. 136
11.4.5 Disposal of lubricants and coolants ........................................................................ 137
11.5 Disposal ............................................................................................................................. 137
11.6 RoHS , 2002/95/CE ........................................................................................................... 137
11.7 Product follow-up ............................................................................................................... 138
11.8 EC - Declaration of conformity .......................................................................................... 139
12 Index
© 2009
GB

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OPTIMUM Safety

MASCHINEN - GERMANY

1 Safety
Glossary of symbols

gives further advice

calls on you to act

• Enumeration

This part of the operating manual

• explains the meaning and use of the warning references contained in the operating manual,
• explains how to use the lathe properly,
• highlights the dangers that might arise for you or others if these instructions are not obeyed,
• tells you how to avoid dangers.
In addition to this operating manual, please observe
• applicable laws and regulations,
• legal regulations for accident prevention,
• the prohibition, warning and mandatory signs as well as the warning notes on the lathe.
European standards must be observed during installation, operation, maintenance and repair of
the lathe.
If European standards are not applied in the national legislation of the country of destination, the
specific applicable regulations of each country must be observed.
If necessary, the required measures must be taken to comply with the specific regulation of each
country before the lathe is first used.

ALWAYS KEEP THIS DOCUMENT CLOSE TO THE LATHE FOR FUTURE REFERENCE.

INFORMATION
If you are unable to solve a problem using this manual, please contact us for advice:
OPTIMUM Maschinen Germany GmbH
Dr. Robert-Pfleger-Str. 26
D- 96103 Hallstadt
Telefon: +49 (0) 900 - 19 68 220 (0,49 €/min.)
E-Mail: [email protected]
© 2009 GB

Page 6 Safety Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Safety
OPTIMUM
MASCHINEN - GERMANY

1.1 Safety warnings (warning notes)

1.1.1 Classification of hazards

We classify the safety warnings into various levels. The table below gives an overview of the
classification of symbols (ideogram) and warnings for the specific danger and its (possible) con-
sequences.

Ideogram warning alert Definition/Consequences

Imminent danger that will cause serious injury or death to

DANGER!
persons.

Risk: A danger that might cause serious injury or death to

WARNING!
a person.

Danger or unsafe procedure that might cause injury to

CAUTION!
persons or damage to property.

Situation that could cause damage to the lathe and to the

product and other types of damages.
ATTENTION!
No risk of injury to persons.

Application advice and other important or useful informa-

tion and notes.
INFORMATION
No dangerous or harmful consequences for persons or
objects.

In case of specific dangers we replace the ideogram by

or

general dan- with a warning injuries to hazardous rotating parts.

ger of hands, electrical volt-
age,
© 2009
GB

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MASCHINEN - GERMANY

1.1.2 Further ideograms

Activation forbid- Pull the main plug! Use safety Use ear protec- Use protective
den! glasses! tion! gloves!

Use protective Wear a safety suit! Only switch in Protect the envi- Contact address
boots! standstill! ronment!

1.2 Proper use

WARNING!
In the event of improper use, the lathe
• will endanger personnel,
• will endanger the lathe and other material property of the operator,
• may affect proper operation of the lathe.
The lathe is designed and manufactured to be used in environments where there is no potential
danger of explosion.
The latheis designed and manufactured for straight turning and facing round or regular formed
three-, six- or twelve-square workpieces in cold metal, castings and plastics or similar materials
that do not constitute a health hazard or do not create dust, such as wood. The lathe must only
be installed and operated in a dry and ventilated place.
If the lathe is used in any way other than described above, modified without authorization of
Optimum Maschinen Germany GmbH or operated with different process data, then it is being
used improperly.
We do not take liability for damage caused by improper use.
We would like to stress that any modifications to the construction, or technological modifications
that have not been authorised by Optimum Maschinen Germany GmbH will also render the
guarantee null and void.
It is also part of proper use that
• the maximum values of the lathe are compiled with,
• the operating manual is observed,
• inspection and maintenance instructions are observed.
“Technical Data“ on page 18
In order to achieve optimum cutting performance, it is essential to choose the right turning tool,
feed, tool pressure, cutting speed and coolant.
© 2009 GB

Page 8 Safety Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Safety
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WARNING!
Very serious injury due to improper use.
It is forbidden to make any modifications or alternations to the operating values of the
lathe. They could endanger personnel and cause damage to the lathe.

1.3 Possible dangers caused by the lathe

The lathe has undergone a safety inspection. The construction and design are state of the art.
Nevertheless, there is a residual risk as the lathe operates with
• high revolutions,
• rotating parts,
• electrical voltage and currents.
We have used construction resources and safety techniques to minimize the health risk to per-
sons resulting from these hazards.
If the lathe is used and maintained by personnel who are not duly qualified, there may be a risk
resulting from incorrect operation or unsuitable maintenance.

INFORMATION
All persons involved in assembly, commissioning, operation and maintenance must
• be dully qualified,
• follow this operating manual.
Due to improper use
• there is a risk for personnel,
• the lathe and further property might be endangered,
• the function of the lathe could be affected.
Always disconnect the lathe when cleaning or maintenance work is being carried out.

WARNING!
The lathe may only be used with the safety devices activated.
Disconnect the latheimmediately whenever you detect a failure in the safety devices or
when they are not mounted!
All additional installations carried out by the operator must incorporated the safety
devices presrcibed.
This is your responsibility being the operator ot the lathe!
“Safety devices“ on page 11

1.4 Qualification of personnel

1.4.1 Target group

This manual is addressed to
• the operators,
• the users,
• the maintenance staff.
Therefore, the warning notes refer to both operation and maintenance of the lathe.
Determine clearly and irrevocably who will be responsible for the different activities on the lathe
© 2009

(operation, maintenance and repair).

GB

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MASCHINEN - GERMANY

Vague or unclear assignment of responsibilities constitutes a safety hazard!

Always disconnect the main plug of the lathe and secure the main switch by a lock. This will pre-
vent it from being used by unauthorized persons.

1.4.2 Authorized persons

WARNING!
Incorrect use and maintenance of the lathe constitutes a danger for personnel, objects
and the environment.
Only authorized persons may operate the lathe!
Persons authorized to operate and maintain are technical staff trained and instructed who are
working for the operator and for the manufacturer.

1.4.3 Obligations of the operator

The operator must instruct the staff at least once a year on
• all safety standards that apply to the lathe,
• the operation,
• accredited technical guidelines.
the operator must also
• check the knowledge of the staff,
• document training/instructions,
• require the staff to confirm participation in training/instructions by means of a signature,
• check that the staff is aware of safety and dangers in the workplace and that they observe
the operating manual.

1.4.4 Obligations of the user

The user must
• have read and understood the operating manual,
• be familiar with all safety devices and regulations,
• be able to operate the lathe.

1.4.5 Additional qualification requirements

For work on electrical components or equipment there are additional requirements:
• This work shall only be carried out by a qualified electrcian or a person working under the
instructions and supervision of a qualified electrician.
• Before carrying out work on electric components or operating units, the following measures
must be taken, in the order given.
disconnect all poles.
ensure that the lathe cannot be turned on again,
check that there is no voltage.

1.5 User’s position

The user must stand in front of the lathe.
© 2009 GB

Page 10 Safety Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Safety
OPTIMUM
MASCHINEN - GERMANY

1.6 Safety measures during operation

CAUTION!
Risk due to inhaling of health hazardous dusts and mist.
Dependent on the material which need to be processed and the used auxiliaries dusts
and mist may be caused which might impair you health.
Make sure that the generated health hazardous dusts and mist are safely sucked off at
the point of origin and is dissipated or filtered from the working area. Use an appropriate
suction unit.

CAUTION!
Risk of fire and explosion by using flammable materials or cooling lubricants.
Take additional preventive measures in order to safely avoid health hazards before
processing flammable materials (e.g. aluminum, magnesium) or before using flammable
additives (e.g. spirit).

CAUTION!
Risk of winding-up or cutting damages when using hand tools.
The machine is not designed for the use of hand tools (e.g. emery cloth or files). It is for-
bidden to use any hand tools on this machine.

1.7 Safety devices

Operate the lathe only with properly functioning safety devices.
Stop the lathe immediately if there is a failure in the safety device or if it is not functioning for any
reason.
It is your responsibility!
If the safety device has been activated or has failed, the lathe must only be operated again
when
• the cause of the failure has been removed,
• you have made sure that there is no resulting danger for persons or objects.

WARNING!
If you bypass, remove or override a safety device in any other way, you are endangering
yourself and other persons working on the lathe.
The possible consequences are:
• damage as a result of components or parts of components flying off at high speed,
• contact with rotating parts,
• fatal electrocution,
• pulling-in of clothes.

WARNING!
The separating protective equipment which is made available and delivered together with
the machine is designed to reduce the risk of workpieces or fractions of them which
being expelled, but not to remove them completely.
The lathe includes the following safety devices:
• a lockable main switch,
© 2009

• an EMERGENCY-STOP,
• a lathe chuck protection with position switch,
GB

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• a protective cover on the headstock with position switch,

• a recoil spring as protective cover on the guide spindle. The coil spring prevents the pulling-
in of clothes into the guide spindle.
• an overload clutch on the feed shaft,
• safety screws for the Camlock bolts on the workpiece holder.

1.7.1 Lockable main switch

It is possible to secure the lockable main
with a padlock at the position "0" against
switching on by mistake or unauthorized
switching on.
When the main switch is switched off, the
power supply to the machine is completely main switch
interrupted.

Illustr.1-1: main switch

WARNING!
Dangerous voltage even when the main switch is switched off.
In the areas marked by the ideogram in the margin there might be voltage, even if the
main switch is switched off.

1.7.2 EMERGENCY-STOP
The EMERGENCY-STOP switches the
lathe off.
Knocking on the emergency stop device
triggers an emergency stop. EMERGENCY-
STOP
After actuating the switch, turn it to the
right, in order to restart the lathe.

Illustr.1-2: EMERGENCY-STOP

1.7.3 Protective cover with safety switch

The spindle head of the lathe is equipped
with a fixed, separating protective cover.
The locked position is monitored by
Integrated position
means of an electrical limit switch. switch
INFORMATION
It is not possible to start the machine until
the protective cover is closed.
Protective cover
© 2009 GB

Illustr.1-3: Protective cover of spindle head

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Safety
OPTIMUM
MASCHINEN - GERMANY

1.7.4 Lathe chuck protection with position switch

The lathe is provided with a lathe chuck
protection. The lathe can only be switched
on when the lathe chuck protection is Protective cover of
closed. lathe chuck closed

Protective cover of
lathe chuck opened

Integrated position
switch

Illustr.1-4: lathe chuck protection

1.7.5 Prohibition, warning and mandatory labels

INFORMATION
All warning labels must be legible. Check them regularly.

Abb.1-5: warning labels

© 2009
GB

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1.8 Safety check

Check the lathe at least once per shift. Inform the person responsible immediately of any dam-
age, defect or change in operating function.
Check all safety devices
• at the brginning of each shift (with the machine stopped),
• once a week (with the machine in operation),
• after every maintenance and repair work.
Check the prohibition, warning and information labels as well as the markings on the lathe
• are legible (clean them, if necessary),
• are complete.

INFORMATION
se the following table in order to organize the checks.

General check

equipment check OK

Protective covers mounted, firmly bolted and not damanged

Labels, markings installed and legible

Date: checked by (signature):

Functional check

equipment check OK

EMERGENCY-STOP When the EMERGENCY-STOP switch is activated, the

lathe should switch-off automatically

Position switch of the The lathe shall only run with the lathe chuck protection
lathe chuck protection closed

Position switch for the The lathe shall only turn on if the protective cover is
protective cover of the mounted to the headstock
headstock

Date: checked by (signature):

© 2009 GB

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OPTIMUM
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1.9 Personal protective equipment

For certain work personal protective equipment is required.
Protect your face and your eyes: Wear a safety helmet with a face guard for all work, especially
for work where your face and eyes are exposed to hazards.

Use protective gloves when lifting or handling pieces with sharp edges.

Wear safety shoes when fitting, dismantling or transporting heavy components.

Use ear protection if the noise level (immission) in the workplace exceeds 80 dB (A).
Before starting work, make sure that the prescribed personal equipment is available at the work-
place.

CAUTION!
Dirty or eventually contaminated personal protective equipment might cause disease.
Clean it after every use and once a week.

1.10 Safety during operation

In the description of work with and on the lathe we highlight the dangers specific to that work.

WARNING!
Before activating the lathe, double check that this will not endanger other people or
cause damage to equipment.
Avoid unsafe working practice:
• Make sure, your work does not endanger anyone.
• Clamp the workpiece tightly before activating the lathe.
• Mind the maximum chuck opening.
• Use safety glasses.
• Do not remove turning chips by hand. Use a chip hook and / or a handbrush to remove turn-
ing chips.
• Clamp the turning tool at the correct heigh and with the least possible overhang.
• Turn off the lathe before measuring the workpiece.
• The instructions of this manual must be observed strictly during assembly, operation, mainte-
nance and repair.
• Do not work on the lathe if your concentration is reduced, for example, because you are tak-
ing medication.
• Observe the regulations for the prevention of accidents issued by your association for the
prevention of occupational accidents and safety in the workplace or other inspection authori-
ties.
• Inform the inspector of any danger or failure.
• Stay at the lathe until all rotating parts have come to halt.
• Use the prescribed personal protective equipment. Make sure to wear a well-fitting work suit
and a hairnet, if necessary.
© 2009
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OPTIMUM Safety

MASCHINEN - GERMANY

1.11 Safety during maintenance

Inform the operating staff in good time of any repair and maintenance work.
Report all safety-relevant changes or performance details of the lathe. Document all changes,
have the operating manual changed accordingly and train the machine operators.

1.11.1 Switching-off and securing the lathe

Turn off the main switch of the lathe before starting any maintenance or repair work.
Secure the main switch by a lock against unauthorized switching on and keep the key in a safe
place.
All machine components and hazardous voltages are disconnected.
Except the areas marked by the ideogram in the margin. In these areas there might be voltage
even if the main switch is disconnected.
Attach a warning sign on the lathe.

WARNING!
Live components and movement of machine parts may cause severe injury to you or
other persons!
If the work requires (e.g. in case of a functional control) not to pull the main plug of the
lathe, proceed with extreme care.

1.11.2 Use of lifting equipment

WARNING!
Use of unstable lifting and load - suspension gear that might break under load can cause
very serious injuries or even death.
Check that the lifting and load suspension gear is of sufficient load capacity and in per-
fect condition.
Observe the regulations for the prevention of accidents issued by your association for
the prevention of occupational accidents and safety in the workplace or other inspection
authorities.
Fasten the loads properly.
Do not walk under lifted loads!

1.11.3 Mechanical maintenance work

Remove all protection and safety devices before starting maintenance work and re-install them
once the work has been completed, such as:
• covers,
• safety indications and warning signs,
• earth (ground) connection.
If you remove protection or safety devices, refit them immediatelly after completing the work.
Check if they are working properly!
© 2009 GB

Page 16 Safety Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Safety
OPTIMUM
MASCHINEN - GERMANY

1.12 Accident report

Inform your superiors and Optimum Maschinen Germany GmbH immediately in case of acci-
dents, possible sources of danger and any actions which almost led to an accident("near
misses").
"Near misses" may have many possible causes.
The sooner they are notified, the faster these causes can be eliminated.

INFORMATION
In the description of execution of work with and on the lathe we highlight the dangers specific to
that work.

1.13 Electrical system

Have the machine and / or the electrical equipment checked regularly, but at least every six
months. Eliminate immediately all defects such as loose connections, defective wires, etc.
A second person must be present during work on live components, to disconnect the power in
case of an ermergency. Disconnect the lathe immediately if there is a mulfunction in the power
supply!
“Maintenance“ on page 78
© 2009
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OPTIMUM Technical Data

MASCHINEN - GERMANY

2 Technical Data
The following data give dimensions and weight and are the manufacturer’s authorized machine
data.

2.1 power connection

Total connection rate 3 x 400V 1,5 KW 50 Hz
driving power spindle motor 1,5 KW
control voltage 24 V 63 VA

2.2 Machine data

diameter three-jaw chuck [mm] 160
distance between centres [mm]
1000
(when using a dead center)
swing over machine bed [mm] 330
swing over support [mm] 198
swing in the bed gap [mm] 476
bed dimension [mm] 186
-1]
spindle speed [min 70 | 115 | 190 | 300 | 460 | 755 | 1255 | 2000
number of steps 8
spindle cone MK 5
spindle seat Camlock ASA D 1 - 4"
travel compound slide [mm] 170
scale compount slide 1 scale line = 0,04mm
travel top slide [mm] 85
scale top slide 1 scale line = 0,04mm
adjustment range top slide + - 90°
taper bore tailstock sleeve MK 3
tailstock -sleeve lifting [mm] 126
tailstock - cross adjustment [mm] 10
tailstock - sleeve diameter [mm] 45
longitudinal feed [mm/U] 0,097 - 2,713
thread pitch lead spindle 2,5 mm
crossfeed [mm/U] 0,033 - 0,933
pitch - metric [mm/U] in a range of 0,4 - 7
pitch - inch [threads/inch] in a range of 56 - 4
Modular threads 0,2 - 3,5
Diametrically threads 8 - 120
max. seat hight cutting tool
or cutting tool seat in the 30
quadruple seat [mm]
level difference between bearing surface quad-
17,5
ruple seat and turning centre [mm]
rod passage follow rest [mm] 95
rod passage steady rest [mm] 100
diameter face plate [mm] 320
© 2009 GB

Page 18 Technical Data Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Technical Data
OPTIMUM
MASCHINEN - GERMANY

2.3 dimensions
height [mm] 1300
length [mm] 1930
depth [mm] 755
total weight [kg] 660
floor loading 6 KN / m2

2.4 working area

height [mm] 2000
length [mm] 2600
depth [mm] 2400

2.5 environmental conditions

temperature 5 - 35 °C
humidity 25 - 80 %

2.6 operating material

Mobilgear 627 or other eqiuvalent oil,
headstock
filling quantity 2 litres
Mobilgear 629 or other equivalent oil,
gear of apron
filling quantity 0,4 litres
Mobilgear 629 or other equivalent oil,
feed gear
filling quantity 0,6 litres
bright steel parts and lubricating nipples acid-free lubricating oill

2.7 Emissions
The level of noise emitted by the lathe is 84 dB(A) at no-load operation.

INFORMATION
This numeric value had been measured on a new machine under conventional operating condi-
tions. Depending on the age or wear of the machine, the noise behavior of the machine might
change.
Furthermore, the extent of the noise emission is also depending on manufacturing
influence factors, such as speed, material and clamping conditions.

INFORMATION
The mentioned numerical value is an emission level and not necessarily a safe
working level.
Unless the degree of noise emission and the degree of noise disturbance are depending on one
another it is not possible to use it in order to reliably determine if it is necessary to take further
preventive measures or not.
The following factors influence the actual degree of the noise disturbance of the
operator:
• Characteristics of the working chamber, e.g. size or damping behavior,
• Other noise sources, e.g. the number of machines,
© 2009

• Other processes proceeding nearby and the period during which the operator is exposed to
the noise.
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OPTIMUM Technical Data

MASCHINEN - GERMANY

Furthermore, the admissible pollution level may be different from one country to another due to
the national regulations.
This information regarding the noise emission should allow the operator of the machine to per-
form a better evaluation of the endangerments and risks.

CAUTION!
The machine operator has to wear an appropriate ear protection depending on the overall
stress caused by noise and on the basic limit values.
We generally recommend using a sound and ear protection.

© 2009 GB

Page 20 Technical Data Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Technical Data
OPTIMUM
MASCHINEN - GERMANY

2.8 Dimensions, installation plan D330x1000

© 2009

Abb.2-1: Dimensions, installations plan D330x1000

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OPTIMUM Technical Data

MASCHINEN - GERMANY

2.9 Dimensions, installation plan D330x1000 DPA

© 2009 GB

Abb.2-2: Dimensions, installations plan D330x1000 DPA

Page 22 Technical Data Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Assembly
OPTIMUM
MASCHINEN - GERMANY

3 Assembly
INFORMATION
The lathe is delivered pre-assembled.

3.1 Delivery volume

When the lathe is delivered, please check immediately that it has not been damaged during
transport and that all components are included. Also check that no fastening screws have come
loose. Compare the delivery volume to the indications on the packing list.

3.2 Transport

Center of gravity

Attachment positions (marking the positions for

the attachment position gear)

Prescribed transport position (marking the top

side)

Means of transportation to be used

Weights

WARNING!
Machine parts which fall off forklift trucks or other transport vehicles could cause very
serious or even fatal injuries. Follow the instructions and information on the box.

WARNING!
Use of unstable lifting and load suspension gear that breaks under load can cause very
serious injuries or even death.
Check that the lifting and load suspension gear has sufficient load capacity and is in
perfect condition. Observe the rules for preventing accidents issued by your association
for the prevention of occupational accidents and safety in the workplace or other
inspection authorities.
Hold the loads properly. Never walk under suspended loads!
© 2009
GB

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MASCHINEN - GERMANY

3.3 Storage

ATTENTION!
Improper storage may cause important parts to be damaged or destroyed.
Store packed or unpacked parts only under the following ambient conditions.
Please follow the instructions and indications on the transportation box.

Fragile goods (goods require careful handling)

Protect against humidity and humid environments

“environmental conditions“ on page 19.

Prescribed position of the packaging box (marking

the top side – arrows pointing upward)

Maximum stacking height

Example: non-stackable – do not pile any further

packaging boxes on top of the first packaging box

Consult Optimum Maschinen Germany GmbH if the lathe and accessories have to be stored
for a period of over three months or under different external conditions than those given here
“Information“ on page 6.

3.4 Installation and assembly

3.4.1 Requirements of the installation site

ATTENTION!
Before installing the machine, have the load bearing capacity of the subsoil checked by a
specialist. The floor and the ceiling of the hall have to bear the weight of the machine
plus all additional parts and additional aggregates as well as the operator and the
stocked materials. Reinforce the subsoil, if necessary.
© 2009 GB

Page 24 Assembly Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Assembly
OPTIMUM
MASCHINEN - GERMANY

INFORMATION
In order to provide for good functionality and high machining accuracy as well as long durability
of the machine the site should fulfill certain criteria.
Observe the following items:
• The device must only be installed and operated in dry ventilated places.
• Avoid places nearby machines generating chips or dust.
• The site has to be vibration-free, i.e. at a distance from presses, planing machines, etc.
• The substructure has to be appropriate for turning. Also make sure that the load bearing
capacity and the evenness of the floor are appropriate.
• The substructure has to be prepared in a way that possibly used coolant cannot penetrate
into the ground.
• Protruding parts such as stops, handles, etc. need to be secured by measures provided by
the customer if necessary in order to avoid dangers for persons.
• Provide sufficient space for assembly and operating staff as well as for material transport.
• Also allow for accessibility for setting and maintenance works.
• Make sure that the mains plug of the turning machine is freely accessible.
• Provide for sufficient illumination (minimum value: 300 lux, measured at the tool tip). In case
of little intensity of illumination provide for additional illumination i.e. by a separate workplace
illuminator.

INFORMATION
The mains plug of the lathe has to be freely accessible.

3.4.2 Load end position

INFORMATION
If your lathe is being delivered with a machine substructure, use the through holes in the
machine substructure as a load end support.
Put an adequately thick piece of steel with a diameter of 30 to 34mm (round steel, thick -
walled tube) through the hole of the machine substructure.
Suspend a lifting loop to each of the two sides of the lathe bed and to the ends of the piece of
steel.

drill hole in the machine bed

for the load end position

Illustr. 3-1: drill hole for the load end position

Make sure that you have an equal load end position and that the lathe will not overturn when
it is being lifted.
© 2009

Make sure that no add - on pieces or varnished parts are damaged due to the load suspen-
sion.
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3.4.3 Installation

WARNING!
Danger of crushing and overturning. The installation of the lathe must be performed by at
least two persons.
Check the foundation of the lathe with a water spirit on horizontal alignment.
Check the foundation on sufficient soil bearing capacity and rigidity.
“Dimensions, installation plan D330x1000“ on page 21
“Dimensions, installation plan D330x1000 DPA“ on page 22

ATTENTION!
Insufficient rigidity of the foundation leads to the superposition of vibrations between the
lathe and the foundation (natural frequency of components). Insufficient rigidity of the
entire lathe assembly also rapidly causes the lathe to reach critical speeds, with unpleas-
ant vibrations, leading to bad turning results.

3.4.4 Anchoring-free assembly

If required, use the washers com-
prised in the delivery volume for
the lathe’s substructure.
Adjust the lathe by means of a
spirit level for machines.
• Check the adjustment once again
after a few days of operation.

holes

holes

Illustr.3-2: Installation
© 2009 GB

Page 26 Assembly Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Assembly
OPTIMUM
MASCHINEN - GERMANY

3.4.5 Anchored assembly

Use the anchored assembly in order
to relize a stiff attachment to the foun-
dation. The anchored assembly is
always useful if it is intended to treat
big parts up to the maximum capacity
of the lathe.
vibration and noise reduced
material

threaded rod as anchored rod,

optionally
shear connector-cartridge M12

Illustr.3-3: drawing anchoring

3.5 First use

WARNING!
Personnel and equipment may be endangered if the lathe is first used by inexpert per-
sonnel. We do not take any liability for damages caused by incorrect commissioning.

3.5.1 Cleaning and greasing

Remove the anti-corrosive agent applied to the lathe for transport and storage purposes. We
recommend the use of kerosene.
Do not use any solvents, thinner or other cleaning agents which could corrode the varnish on
the lathe. Follow the specifications and indications of the manufacturer of the cleaning agent.
Lubricate all bright machine parts with acid-free lubricating oil.
Grease the lathe according to the lubrication chart
. “Maintenance“ on page 78

3.5.2 Visual inspection

Check the oil level in the inspection glass of the spindle head, of the feed gear and of the apron.
“Oil-sight glasses“ on page 81, filling quantity “operating material“ on page 19

3.5.3 Functional check

Check free movement of all spindles.

3.5.4 Power connection

For power connection via plug, use a type CEE-400V-16A plug.
“Qualification of personnel“ on page 9, “Schaltplan - Wiring diagram D330x1000“ on
page 128, “Schaltplan - Wiring diagram D330x1000 Vario“ on page 130
Check the fuse protection of your power supply to the technical data for the total connection
value of the lathe.
© 2009
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MASCHINEN - GERMANY

ATTENTION!
For 400V machines: Imperatively make sure that all 3 phases (L1, L2, L3) are connected
correctly.
Most of the defects on motors are resulting from wrong connections. For instance, if a
motor phase is not correctly clamped or connected to the neutral conductor (N).
This may cause:
• That the motor is becoming hot very rapidly
• Increased motor noises.
• The motor has no power.
If the machine is wrongly connected the warrantee will become null and void.

ATTENTION!
Lathes with frequency converter should not be operated with a CEE plug. Connect the
machine permanently to a connection box (see EN 50178 / VDE 5.2.11.1)
• D 330 x 1000 Vario

INFORMATION
The frequency converter (driving regulator) might release the FI protected switch of your
electrical supply. In order to avoid any malfunctioning, you either need an FI protected switch
sensitive for pulse current or an AC/DC sensitive one.
In case of a malfunction or release of the FI protected switch, please check the type installed.
The following signs indicate if you have one of the FI protected switches described above.
FI protected switch sensitive to pulse current FI protected switch sensitive to AC/DC
type A type B

300 mA 300 mA

We recommend you to use an FI protected switch sensitive to AC/DC. FI protected switches

sensitive to AC/DC (RCCB, type B are adequate for 1 phase and 3 phase feed frequency
converters (driving regulators).
An FI protected switch type AC (only for alternating current (AC)) is not appropriate for
frequency converters. FI protected switches type AC are no longer used.

3.5.5 Functional test

Carry out a safety test. “Safety check“ on page 14
Check the turning direction of the lathe chuck flange. It must turn anti-clockwise with the con-
trol lever at the apron turned down.

3.5.6 Coolant provision

Fill in coolant. Use a water-soluble emulsion not being harmful to the environment which you
can buy in specialized trades. Filling quantity “operating material“ on page 19
© 2009 GB

Page 28 Assembly Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Assembly
OPTIMUM
MASCHINEN - GERMANY

3.6 Optional accessories

WARNING!
Risk by using improper workpiece clamping materials or by operating the machine with
inadmissible speed.
Only use the clamping materials (e.g. lathe chuck) which had been delivered together
with the machine or as optional equipment offered by OPTIMUM.
Use the working clamping materials only in the provided admissible speed range.
Workpiece clamping materials must only be modified according to the recommendations
of OPTIMUM or of the clamping material manufacturer.

item No

3-jaw chuck
344 1531
200 mm

4-jaw chuck
344 1532
200 mm

follow lathe center

344 1503
MK3

universal collet chuck device

344 1506
5C

set of collet chucks

3 to 25 mm,
344 1509
17 pieces,
5C

quick action tool holder SWH 3-E

consisting of:
1 tool holder head 338 4303
3 tool holders 20 x 100 for square tool
1tool holder 30 x 100 for moil chisel
© 2009
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MASCHINEN - GERMANY

set of cutting tools

16 mm,
344 1508
11-pieces,
carbide tipped

set of cutting tools

16 mm,
344 1511
7-pieces,
hard metal indexable insert

levelling swing element SE 2

anchoring - free,
338 1016
vibration - isolated,
hight adjustable

© 2009 GB

Page 30 Assembly Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

OPTIMUM
MASCHINEN - GERMANY

4 Levelling- damping element SE1 and SE2

4.1 Mounting:
Positioning the levelling vibration-damping element at the desired site of the machine (holes
in the machine stand).
Check the horizontal direction of each levelling vibration-damping element in about to each
other.
The max. possible height adjustment of each levelling vibration-damping element is:
SE1 - 10mm
SE2 - 12mm
Remove the levelling screw completely.
Compacting the machine to that levelling vibration-damping element.
Assemble the levelling screw (if required, a shorter levelling screw can also be employed).
Check the horizontal direction of the machine - if required - set up the height adjustment by
screwing of the levelling screw in. Screwing in the levelling screw causes that the rubber
plate lifts itself as on the drawing from the same element.
Lock the height adjustment through the levelling screw with the lock-nut.

4.2 Max. weight force per element:

• Lathes, max.: S1 = 3.300 N / S2 = 8.000 N
• Milling machines, max.: S1 = 5.000 N / S2 = 1.300 N
• Surface grinding machine, max.: S1 = 3.300 N / S2 = 8.000 N
• General machines, max.: S1 = 12.000 N / S2 = 30.000 N
• Static maximum weight force: S1 = 20.000 N / S2 = 40.000 N

Foot of the machine / machine stand

Illustr.4-1: Foot of the machine / machine stand SE1/ SE2

© 2009
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22 September 2009 Version 1.2 D330x1000 Lathe Page 31

OPTIMUM
MASCHINEN - GERMANY

4.3 Dimension SE1/ SE2

Levelling screw

Lock-nut

Illustr.4-2: Dimension SE1/ SE2

© 2009
GB

Page 32 Lathe D330x1000 Version 1.2 22 September 2009

Operation
OPTIMUM
MASCHINEN - GERMANY

5 Operation
5.1 Safety
Operate the lathe only under following conditions:
• The lathe is in proper working order.
• The lathe is used as prescribed.
• The operating manual is followed.
• All safety devices are installed and activated.
Any malfunction should be eliminated immediately. Stop the lathe immediately in the event of
any malfunction in operation and make sure it cannot be started up accidentally or without
authorization.
Notify the person responsible of any modification.
“Safety during operation“ on page 15

5.2 Control and indicating elementsBedien- und Anzeigeelemente

DPA2000 (only lathe chuck protection lathe chuck
D330x1000DPA)

follow rest (example)

control panel machine lighting

Speed change lever fixed rest (example)

feed direction selec-

tor lever tailstock

change wheel and

infeed table

control lever left -

selector switch feed hand / right - hand
gear mechanism rotation

feed direction selec-

tor lever

mechanical
control panel spindle brake
lathe saddle

Illustr. 5-1: D330x1000 DPA

© 2009
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MASCHINEN - GERMANY

5.2.1 Overview of the control elements

feed direction selector

lockable main switch speed adjustment selector lever
lever
rapid break

control light selector switch feed feed adjustment

EMERGENCY-STOP gear mechanism selector lever
for operation

trip lever thread cut- control lever turning trip lever crossfeed /
thread gauge
ting direction longitudinal feed

quadruplicate tool lathe saddle tighten-

lathe chuck tailstock
holder ing screw
© 2009 GB

Page 34 Operation Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Operation
OPTIMUM
MASCHINEN - GERMANY

5.2.2 Overview of indicating elements

scale on the hand-

oil-sight glass oil-sight glass head-
oil-sight glass apron wheels
feedgear mechanism stock
( here tailstock )

scale crossfeed offset

scale thread gauge
tailstock

5.2.3 Control elements

inch thread metric thread

[ threads / inch ] [ mm / spindle revolution ]

feed direction feed direction

forward (left-handed thread) backward (right-handed thread)

turning direction clockwise turning direction counter-clockwise

lead screw-nut disengaged lead screw-nut engaged

© 2009

longitudinal feed crossfeed

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OPTIMUM Operation

MASCHINEN - GERMANY

5.3 Speed adjustment

ATTENTION!
Only change the speed when the lathe is completely stopped.
There are 8 speeds at disposal.
Use the rapid brake to facilitate the locking of the switching position.

5.3.1 Turning direction

The lathe is switched on and off with the ON
OFF control lever. The lathe only runs with the
lathe chuck protection closed.
Turn the control lever down if you want the control lever
turning direction to be anti-clockwise.
Turn the control lever up if you want the
turning direction to be clockwise.

Illustr.5-2: control lever spindle

ATTENTION!
Wait until the lathe has come to a complete
halt before inverting the turning direction
using the control levers. Use the spindle
brake to slow down the lathe more quickly.
spindle brake
Changing the turning direction during oper-
ation may cause damage to components.

Illustr.5-3: spindle brake

5.4 Feed
Set the transverse or longitudinal feed or the
required pitch for thread turning with the selec-
tor lever and with the selector switch.

ATTENTION!
Only change the indexing position when
the machine has come to a complete halt. If
required, use the rapid break to facilitate
the engaging of the indexing position.

rapid break

Illustr.5-4: feed selector switch

© 2009 GB

Page 36 Operation Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Operation
OPTIMUM
MASCHINEN - GERMANY

5.4.1 Feed direction

The selector lever is used to change the feed
direction.
Turn the selector lever up or down according to
the symbols if you want to make a left-handed or
a right-handed thread.
selector switch
feed direction

Illustr.5-5: Control panel headstock

5.5 Tool holder

Clamp the turning tool into the toolholder.
The tool must be clamped firmly and with the
least possible overhang in order to absorb well
and reliably the cutting force generated during the
chip formation. Tool holder

“level difference between bearing surface

quadruple seat and turning centre [mm]“ on page
18

Illustr.5-6: Tool holder

Adjust the height of the tool. Use the tailstock with lathe centre to adjust the tool to the required
height. If necessary, use steel spacer shims under the tool to get the required height.

Tool height
For the facing process, the cutting edge of the tool must be exactly aligned with the height of the
lathe centre to obtain a shoulder-free face. The facing process is a turning operation in which
the turning tool feeds perpendicular to the axis of rotation of the workpiece in order to produce a
flat surface. The different methods are transversal facing, transversal slicing and longitudinal
facing.

Tool adjusted to Tool adjusted above Tool adjusted below

centre heightt centre height. centre height
Illustr. 5-7: height of the tool
© 2009
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OPTIMUM Operation

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Tool angle

ATTENTION!
The tool must be clamped with its axis perpendicular to the axis of the workpiece. If it is
clamped at an angle, the tool may be sucked into the workpiece.

incorrect
correct

Tool clamped perpendicular to the Tool clamped at an angle to the

axis of the workpiece. feed direction.

Illustr. 5-8: angle of the tool

5.6 Switching the lathe on

5.6.1 Main switch

Turn the main switch on.

The control lamp for operation must be on.

Check that the EMERGENCY-STOP button is not pressed or unclamped. Turn the
EMERGENCY-STOP button to the right in order to unclamp it.
Close the lathe chuck protection.

5.7 Head spindle seat

The head spindle is designed as Camlock ASA
clamp bolt
D 1-4" - holding fixture.

CAUTION!
Regularly check the closed status of the
clamp bolt.

INFORMATION Camlock -
bolt seats
Mark each workpiece holder by a nick in
order to facilitate the recover of the preci-
sion of the concentric run and the axial
run-out deviation.
Illustr.5-9: Head spindle seat
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Operation
OPTIMUM
MASCHINEN - GERMANY

Fasten workpiece holder

Fasten the workpiece holder by turning the clamp hold clockwise.
The right clamp position is achieved when the reference marks at the clamp holder are between
the two marks at the lead spindle seat.

V Marking clamp bolt V Marking clamp bolt

"open position" "closed position"
V

V
Illustr.5-10: Marking Camlock bolt

Adjusting the Camlock bolts to the workpiece holder

Detach the safety screw.
reference mark
Turn the Camlock bolt by one complete revolu-
tion in or out, according to the correction nec-
essary. Camlock-
bolt
Mount the safety screw.

INFORMATION safety screw

The reference mark on each Camlock bolt serves

as orientation for the right adjustment.
Illustr.5-11: Camlock-seat

5.7.1 Lathe chuck

The workpieces must be clamped firmly and securely onto the lathe before they are machined.
The clamp should be tight enough to ensure that the workpiece is moved correctly, but not so
tight that it is damaged or deformed.

WARNING!
Do not clamp any workpieces that exceed the permitted chucking capacity of the lathe
chuck. The clamping force of the chuck is too low if it’s capacity is exceeded. The jaws
might work loose.

5.7.2 Mounting workpiece holders

Centre
Clean the taper bore of the head spindle hold-
ing fixture.
Clean the Morse taper and the taper of the
centre.
Press the centre with the Morse taper into the
taper bore of the head spindle holding fixture.

Illustr.5-12: centre
© 2009
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Face plate
Check that the seatings at the head spin-
dle holding fixtures and at the flange to be
fitted are clean and that the supporting sur-
faces are not damaged.
Check that all clamping bolts in the head
spindle holding fixture are opened.
Mount the face plate to the head spindle
seat.
Fix the clamp bolt as described under
“Head spindle seat“ on page 38 beschrie-
ben.
Illustr.5-13: Face plate

5.8 Mounting of rests

5.8.1 Follow and steady rests

Use follow or steady rests to support long turned parts if the shear forces of the turning tool
would bend the turning parts.

Illustr.5-14: follow rest steady rest

INFORMATION
The maximum passage of the steady rest is: 100mm
The maximum possible rod diameter for the follow rest is: 90mm

5.9 Bed insert

Remove the bed insert if the diameter of the
workpiece turned is larger than 356 mm. By fastening screws
removing the bed insert, the diameter turned
might be increased to 516 mm. The turning lenght
is limited to 160 mm.
alignment pins
First detach the fastening screws.
Then pull out the alignment pins. bed insert

For reassembly proceed the other way

around.
© 2009 GB

Illustr.5-15: Bed insert

Page 40 Operation Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Operation
OPTIMUM
MASCHINEN - GERMANY

5.10 Feed tables

5.10.1 Metric threads / longitudinal turning

Indication of pitch in mm [ mm per spindle revolution]

40

127 M L K L N K J N J
60 S S S U S U S U U
A C 3,20 3,60 4,00 4,50 4,80 5,00 5,60 6,00 7,00

B C 1,60 1,80 2,00 2,25 2,40 2,50 2,80 3,00 3,50

A D 0,80 0,90 1,00 - 1,20 1,25 1,40 1,50 1,75

B D 0,40 0,45 0,50 - 0,60 - 0,70 0,75 -

Indication of feed in mm [ mm per spindle revolution ]

30
85
100 P P P P P
U T S V R
1,142 - 1,015 - 0,914 - 0,762 - 0,653 -
A C
- 0,309 - 0,275 - 0,248 - 0,206 - 0,177
0,571 - 0,508 - 0,457 - 0,381 - 0,326 -
B C
- 0,155 - 0,138 - 0,123 - 0,103 - 0,089
0,286 - 0,254 - 0,228 - 0,19 - 0,163 -
A D
- 0,077 - 0,068 - 0,062 - 0,052 - 0,044
0,143 - 0,127 - 0,114 - 0,096 - 0,082 -
B D
- 0,039 - 0,035 - 0,031 - 0,026 - 0,022

30
127
120
40 P P P P P
U T S V R
2,713 - 2,412 - 2,171 - 1,809 - 1,551 -
A C
- 0,933 - 0,829 - 0,746 - 0,622 - 0,533
1,357 - 1,206 - 1,085 - 0,904 - 0,775 -
B C
- 0,466 - 0,414 - 0,373 - 0,311 - 0,266
0,678 - 0,603 - 0,543 - 0,452 - 0,388 -
A D
- 0,233 - 0,207 - 0,187 - 0,155 - 0,133
0,339 - 0,302 - 0,271 - 0,226 - 0,194 -
B D
- 0,116 - 0,103 - 0,093 - 0,078 - 0,067
© 2009
GB

22 / 09 / 2009 Operation Lathe D 330 x 1000 ; Version 1.2 Page 41

OPTIMUM Operation

MASCHINEN - GERMANY

Adjust feed
Example: feed 0,096 mm / spindle revolution

position change wheel

Set selector Set selector Set selector lever Set selector lever
top 30 teeth
switch to position: switch to position: to position: to position:
center 85 teeth
B D P V
bottom 100 teeth
Detach the clamping screw on the lathe saddle at longitudinal
( Illustr.5-24: “lathe saddle tightening screw“ on page 47)
Activate the automatic longitudinal feed by pulling out the lever to the
right and then pushing it up.
Activate the automatic transverse feed by pushing the lever to the left
and then lowering it.
Move the handwheel of the corresponding slide to facilitate the lock-
ing of the engaging lever.

“Cutting speeds“ on page 44

© 2009 GB

Page 42 Operation Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Operation
OPTIMUM
MASCHINEN - GERMANY

Adjusting threads

feed direction selector

lever

Example: thread pitch 3 mm ( M 24 )

change wheel posi- Set selector lever

tion: to position B
Set selector lever Set selector lever
top 40 teeth Select left - Set selector lever to position: to position:
handed or right - to position C
center 127 teeth N U
handed threat with
bottom 60 teeth Feed direction

Detach the clamping screw at the lathe saddle

( Illustr.5-24: “lathe saddle tightening screw“ on page 47)
Activate the automatic feed by the engaging lever thread-cutting.
Move the handwheel of the lathe saddle a little in order to facilitate
the locking of the engaging lever.

5.10.2 Thread based on inch - system

Indication of thread pitch in

[number of turns (treads) on the length of one inch]

40 N M M M M M M M
127
120 V T S S S V S R

40 40 40 44 46 40 52 40

A C 4 4 1/2 5 5 1/2 5 3/4 6 6 1/2 7

B C 8 9 10 11 11 1/2 12 13 14

A D 16 18 20 22 23 24 26 28

B D 32 36 40 44 46 48 52 56
© 2009
GB

22 / 09 / 2009 Operation Lathe D 330 x 1000 ; Version 1.2 Page 43

OPTIMUM Operation

MASCHINEN - GERMANY

5.10.3 Modular threads

44
120 M L K L N K J N J

42 S S S U S U S U U

A C 1,6 1,8 2 2,25 2,4 2,5 2,8 3 3,5

B C 0,8 0,9 1 - 1,2 1,25 1,4 1,5 1,75

A D 0,4 0,45 0,5 - 0,6 - 0,7 0,75 -

B D 0,2 - 0,25 - 0,3 - 0,35 - -

5.10.4 Diametrically threads (trapezoid)

M M M M M M M M
50
V T S S V S R S
120
30 30 30 33 30 36 30 45

A C 8 9 10 11 12 13 14 15

B C 16 18 20 22 24 26 28 30

A D 32 36 40 44 48 52 56 60

B D 64 72 80 88 96 104 112 120

5.10.5 Change of position of the change gear wheels

The change gears for the feed are mounted to a quadrant or directly on the leadscrew.
Unplug the lathe at the main switch
and secure the main switch by a
padlock against unauthorized or
accidental activation.
Open the protective cover of the
change wheels. hexagon socket
screw
Loosen the locking screw on the
quadrant.
Slew the quadrant up.
Open the hexagon socket screw of
the change wheels.

locking screw

Illustr.5-16: change wheels

Mount and position the change wheels as indicated on.

Position the quadrant in a way that the toothed wheels are cammed in.

INFORMATION
Adjust the clearance of the tooth profile with the help of a piece of paper (80g/m2). Clamp the
paper as a spacing between the tooth profiles of the toothed wheels.
© 2009 GB

Page 44 Operation Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Operation
OPTIMUM
MASCHINEN - GERMANY

5.10.6 Threading gauge

The threading gauge is used to cam in the lead - screw nut in connection with the starting lever
thread at the right place with the leading spindle when cutting threads.

ATTENTION!
Dismount or disengage the toothed wheel of the threading gauge when you are not cutting a
thread. The wear and tear of the toothed wheel is reduced considerably.

Metric thread
= indication pitch
Number on scale

T = indication of the number of teeth

on the change wheel

Compare the thread to be cut with the gauge

indication in the threading gauge.
Mount the toothed wheel according to leading spindle
the table.

Cam in the threading gauge with the

toothed wheel
leading spindle.
Tighten the clamping screw.
Close the starting lever thread-cutting.
Turn the scale until there is a figure on
the level of the marking. clamping screw

Only close the starting lever threading

gauge after a cutting thread cycle when
the figure with the marking corresponds starting lever thread
cutting
to the indications on the table on the
threading gauge.

scale

marking
© 2009

Illustr.5-17: gauge
GB

22 / 09 / 2009 Operation Lathe D 330 x 1000 ; Version 1.2 Page 45

OPTIMUM Operation

MASCHINEN - GERMANY

5.11 Tailstock
The tailstock sleeve is used to hold the
tools (bits, centres, etc.). clamping lever

Clamp the required tool in the tailstock

sleeve.
tailstock sleeve with
• Use the scale on the sleeve to re-adjust scale
and/or adjust the tool.
Clamp the sleeve with the clamping
lever. hand wheel

Illustr.5-18: tailstock
• Use the handwheel to move the sleeve back and forth.
The sleeve of the tailstock can be use to introduce a drill chuck for holding bits and counter-
sinks.

5.11.1 Cross-adjustment of the tailstock

The cross-adjustment of the tailstock is
used for turning long, thin bodies.
Loosen the adjusting screws in the front
and in the rear of the tailstock.
adjusting screw in the
front

scale

Illustr.5-19: cross-adjustment of the tailstock

• By alternately loosening and tightning
the two (front and rear) adjusting
screws, the tailstock is moved out of the
central position. The desired cross-
adjustment can be read off the scale.
Firmly retighten the locking screw of the
tailstock.

Illustr.5-20: cross-adjustment of the tailstock

INFORMATION
The tailstock may be cross-adjusted back and forth by approximately 10 mm.
Example:
A 300 mm long shaft is to be taper-turned between the centres with an angle of 1°.
Cross-adjustment of the tailstock = 300 mm x Tan 1°. The tailstock must be cross-adjusted by
approximately 5,236 mm.
© 2009 GB

Page 46 Operation Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Operation
OPTIMUM
MASCHINEN - GERMANY

CAUTION!
Check clamping of the tailstock and the
sleeve, respectively for the turning jobs
between the centres!
Fit the securing screw at the end of the
lathe bed in order to prevent the tail- Securing screw
stock from falling off the lathe bed.

Illustr.5-21: Lathe bed

5.12 General working notes

5.12.1 Streight turning

In the streight turning operation, the tool
feeds parallel to the axis of rotation of the
workpiece. The feed can be either manual-
by turning the handwheel on the lathe sad-
dle or the top slide - or by activating the
automatic feed. The crossfeed for the
depth of cut is achieved using the cross
crossfeed

slide.
feed

Illustr.5-22: graph: streight turning

5.12.2 Facing and recesses

In the facing operation, the tool feeds per-
pendicular to the axis of rotation of the
workpiece. Feed is manual, using the
cross-slide handwheel. The crossfeed for
feed
cut depth is made with the top slide or lathe
saddle.

crossfeed

Illustr.5-23: graph: facing operation

5.12.3 Fixing the lathe saddle

The cutting force produced during facing,
recessing or slicing process may displace
the lathe saddle.
tightening screw
Secure the lathe saddle using the tight-
ening screw.
© 2009

Illustr.5-24: lathe saddle tightening screw

GB

22 / 09 / 2009 Operation Lathe D 330 x 1000 ; Version 1.2 Page 47

OPTIMUM Operation

MASCHINEN - GERMANY

5.12.4 Turning between centres

Workpieces that require a high accuracy and precision are machined between the centres. For
holding purposes, a centre hole is drilled into both plain machined faces of the workpiece.

lathe dog
workpiece

follow centre
600

chuck flange

driving bolt

Vorschub

workpiece
fixed centre 600

Illustr. 5-25: graph: turning between centres

The lathe dog is clamped onto the workpiece. The driving bolt screwed into the flange for the
lathe chuck transmits the torque to the lathe dog.
The fixed centre glides into the centre hole of the workpiece on the spindle nose side. The follow
centre glides into the centre hole of the workpiece at the tailstock side.

5.12.5 Turning short tapers with the top slide

Short tapers are turned manually with the top
slide. Swivel the top slide to the required angle.
The crossfeed is performed with the cross slide.
feed
crossfeed

Illustr.5-26: graph: taper turning

Loosen the two clamping screws in

the front and in the rear of the top front clamping
screw
slide.
Swivel the top slide.
scale "angular
• The required setting of the angular degrees"
degree may be read from the scale.
Clamp the top slide again. top slidet
© 2009 GB

Illustr.5-27: top slide

Page 48 Operation Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Operation
OPTIMUM
MASCHINEN - GERMANY

5.12.6 Thread-cutting
The thread-cutting process requires that the operator has a good knowledge of turning and suffi-
cient experience.

NOTES!
Example of a male thread:
• The workpiece diameter must have been turned to the diameter of the desired thread.
• The workpiece requires a chamfer at the beginning of the thread and an undercut at the
thread runout.
• The speed must be as low as possible.
• The thread cutting tool must be exactly the same shape as the thread, it must be absolutely
rectangular and must be clamped in a ay that it coincides exactly with the turning centre.
• The leadscrew nut (engaging lever) must be engaged during the whole thread-cutting proc-
ess. This does not apply to thread pitches that can be carried out with the threading gauge.
• The thread is produced in various cutting steps in a way that the cutting tool has to be turned
out of the thread completely (with the cross slide) at the end of each cutting step.
• The tool is withdrawn with the leadscrew
nut engaged and the thread cutting tool dis- Thread undercut
engaged by inverting the change-over
switch.
• Stop the lathe and feed the thread cutting
tool in low cut depths using the cross slide.

feed

Illustr.5-28: graph: thread-cutting

• Before each passage, place the top slide approximately 0,2 to 0,3 mm to the left and right
alternately in order to cut the thread free. This way, the thread cutting tool cuts only on one
thread flank with each passage. Keep cutting the thread free until you have almost reached
the full depth of thread.

5.12.7 Coolant
Friction during the cutting process causes high temperatures at the cutting edge of the tool. The
tool should therefore be cooled during the cutting process. Cooling the tool with a suitable cool-
ing lubricant ensures better working results and a longer edge life of the cutting tool.

INFORMATION
Use a water-soluble and non-polluant emulsion as a cooling agent. This can be acquired from
autorized distributors.
Make sure that the cooling agent is properly retrived. Respect the environment when disposing
of any lubricants and cooling agents. Follow the manufacturer’s disposal instructions.
© 2009
GB

22 / 09 / 2009 Operation Lathe D 330 x 1000 ; Version 1.2 Page 49

OPTIMUM Cutting speeds

MASCHINEN - GERMANY

6 Cutting speeds
6.1 Choosing the right cutting speed
Given the many variables involved, it is impossible to give a universally "right" cutting speed.
Tables offering standard cutting speeds should be treated with great circumspection, as they are
only valid for very special cases. The recommended standard values are those laid down in the
papers of the German Committee on Economic Fabrication (AWF) without cooling (no optimum
values). The standard value tables given by the manufacturers of the cutting material should
also be evaluated, e.g., the specifications of Friedrich Krupp Widia-Fabrik, Essen/Gemany, in
the case of hard alloy cutting materials.
ϑc60 is the cutting speed for a tool life of 60 min., whereas ϑc240 is the cutting speed for a tool
life of 240 min. Choose ϑc60 for ordinary, easily replaceable cutting tools, ϑc240 for ordinary tool
sets with mutual dependence, ϑc480 for complicated tool sets which require more time to
exchange due to mutual dependency and the precision of the cutting edges. The same consid-
erations apply to maintenance of the tools. In the case of transfer lines, even higher tool lives
may be preferred.
As a general rule, higher cutting speeds save time and lower cutting speeds save costs.

6.2 Influences on the cutting speed

ϑc = cutting speed in [ m/min]
τ = tool life in [min]
The tool life τ is the length of time in minutes during which the cutting edge keeps cutting until
the wire edge needs to be replaced. It is of great economic importance. With the same material,
the variable τ is indirectly proportional to ϑc, e.g. only a few minutes with ϑc = 2000 m/min. Dif-
ferent materials require different ϑc values for the same τ . Any considerations of this kind
assume that all other cutting conditions remain the same
(materials, tools and settings). If any of these conditions changes, the ϑc value will have to be
changed to get the same τ . For this reason, only cutting speed tables which provide for all pos-
sible cutting conditions are of any use.

6.3 Example for the determination of the required rotation speed on your lathe
The necessary rotation speed depends on the diameter of the workpiece, of the material to be
machined, of the lathe tool as well as of the attitude of the lathe tool (cutting material) to the
workpiece.
Material to be machined: St37
Cutting material (lathe tool): Cemented carbide
Adjusting angle [kr] of cutting tool to workpiece: 90°
Selected feed [f]: approx. 0.16mm per round
Required value of the cutting speed [ϑc] according to table: 180 meter per minute
Diameter [d] of your workpiece: 60mm = 0.06m [meter]

ϑc 180m –1
Rotating speed n = ------------ = --------------------------------------------------- = 955min
π × d min × 3, 14 × 0, 06m

Adjust a rotation speed which appears below determined rotation speed on your lathe.
© 2009
GB

Page 50 Lathe version 1.2 22 September 2009

GB © 2009

Cutting speeds
v22 September 2009
6.4 Cutting speed table
Standard values for cutting speed ϑc in m/min when machining high-speed steel (SS) and hard alloy. (Extract of VDF 8799, Gebr. Boehringer GmbH, Göppingen/Germany)
Tensile
strength
Feed f in mm/rev and tool angle kr 1) 2)
Material
Rm in Cutting 0.063 0.1 0.16 0.25 0.4 0.63 1 1.6 2.5
N material 3)
mm2 45° 60° 90° 45° 60° 90° 45° 60° 45° 90° 45° 60° 45° 60° 90° 45° 60° 90° 45° 60° 90° 45° 60° 90° 45° 60° 90°

St 34; St 37; C22; SS 50 40 34.5 45 35.5 28 35.5 28 22.4 28 22.4 18 25 20 16 20 16 12.5 16 12.5 10
St 42 up to 500 P 10 250 236 224 224 212 200 200 190 180 180 170 160 162 150 140 140 132 125 125 118 112 112 106 100
SS 45 35.5 28 35.5 28 22.4 28 22.4 18 25 20 16 20 16 12.5 16 12.5 10 12.5 10 8
St 50; C 35 500...600
P 10 224 212 200 200 180 170 160 160 150 140 140 132 125 125 118 112 112 106 100 100 95 90
SS 35.5 28 22.4 28 22.4 18 25 20 16 20 16 12.5 16 12.5 10 12.5 10 8 10 8 6.3
St 60; C45 600...700
P 10 212 200 190 190 180 170 170 160 150 150 140 132 132 125 118 118 112 106 106 100 95
SS 28 22.4 18 25 20 16 12.5 16 12.5 16 12.5 10 12.5 10 8 10 8 6.3 8 6.3 5
St 70; C60 700...850
P 10 180 170 160 160 150 140 140 132 125 125 118 112 106 100 95 95 90 85 85 80 75
SS 25 20 16 20 16 12.5 16 12.5 10 12.5 10 8 11 9 7 9 7 5.6 7.5 6 4.5
Mn-; 700...850
P 10 180 170 160 160 150 140 140 132 125 125 118 112 106 100 95 95 90 85 85 80 75
CrNi-,
SS 20 16 12.5 16 12.5 10 12.5 10 8 10 8 6.3 8 6.3 5 7.1 5.6 4.5 5.6 4.5 3.6
CrMo- 850...1000
P 10 140 132 125 125 118 112 100 95 90 90 85 80 71 67 63 63 60 56 56 53 50
& other
version 1.2

alloyed steels SS 14 11 9 11 9 7 9 7 5.6 7 5.6 4.5 5.6 4.5 3.6 4.5 3.6 2.8 3.6 2.8 2.2
1000...1400
P 10 80 75 71 71 67 63 63 60 56 56 53 50 50 47.5 45 45 42.5 40 33.5 33.5 31.5
Stainless steel 600...700 P 10 80 75 71 71 67 63 56 53 50 50 47.5 45 45 42.5 40 33.5 33.5 31.5 31.5 30 28
SS 9 7 5.6 5.6 4.5 3.6 4 3.2 2.5
Tool steel 1500...1800
P 10 45 42.5 40 40 37.5 35.5 35.5 33.5 31.5 28 26.5 25 25 23.4 22 22 21 20 18 17 16
Mn - high-carbon
P 10 33.5 33.5 31.5 31.5 30 28 28 26.5 25 22 21 20 20 19 18 18 17 16
steel
SS 45 35.5 28 35.5 28 22 31.5 25 20 25 20 16 20 16 12.5 16 12.5 10 12.5 10 8
GS-45 300...500
P 10 150 140 132 118 112 106 106 100 95 95 90 85 85 80 75 75 71 67 67 63 60
SS 28 22 18 25 20 16 20 16 12.5 16 12.5 10 12.5 10 8 11 9 7 9 7 5.6
GS-52 500...700
P 10 106 100 95 95 90 85 85 80 75 75 71 67 67 63 60 60 56 53 53 50 47.5
SS 45 40 31.5 31.5 28 22 22 20 16 18 16 12.5 12.5 11 9 11 10 8 9 8 6.3
GS-15 HB...2000
K20 125 118 112 112 106 106 100 95 95 90 85 85 80 75 75 71 67 67 63 60
HB SS 28 25 20 20 18 14 14 12.5 10 11 10 8 9 8 6.3 7.5 6.7 5.3 6 5.3 4.25
GS-25
2000...2500 K10 95 90 85 85 80 75 75 71 67 67 63 60 60 56 53 53 50 47.5 47.5 45 42.5 42.5 40 37.5
GTS-35 SS 37.5 33.5 33.5 28 26.5 25 22 21 20 18 17 16 12.5 12 11 11 10 10 9 8.5 8

OPTIMUM
GTW-40 K10/P10 95 90 85 85 80 75 75 71 67 67 63 60 60 56 53 53 50 47.5 47.5 45 42.5 42.5 40 37.5

MASCHINEN
Chilled casting RC420..570 K10 19 18 17 17 16 15 15 14 13.2 13.2 12.5 11.8 11.8 11.2 10.6 10.6 10 9.5 9 8.5 8 8 7.5 7.1
Cast bronze SS 53 50 47.5 47.5 45 42.5 42.5 40 37.5 37.5 35.5 33.5 31.5 30 28 28 26.5 25 25 23.6 22.4
DIN 1705 K 20 315 300 280 280 265 250 250 236 224 224 212 200 200 190 180 180 170 160 160 150 140 140 132 125
Red bronze SS 75 71 67 63 60 56 50 47.5 45 40 37.5 35.5 31.5 30 28 28 26.5 25 25 23.6 22.4
DIN 1705 K 20 425 400 375 400 375 355 355 335 315 335 315 300 300 280 265 265 250 236 250 236 224 236 224 212
Brass HB SS 112 106 100 90 85 80 67 63 60 50 47.5 45 37.5 33.5 33.5 26.5 25 23.6
DIN 1709 800...1200 K 20 500 475 450 475 450 425 450 425 400 400 375 355 355 335 315 335 315 300 300 280 265 280 265 250
Cast aluminium SS 125 118 112 100 95 85 75 71 67 56 53 50 42.5 40 37.5 31.5 30 28 25 23.6 22.4
300...420
DIN 1725 K 20 250 236 224 224 212 200 200 190 180 180 170 160 160 150 140 140 132 125 125 118 112 118 112 106 100 95 90
Lathe

-
Mg alloy SS 850 800 750 800 750 710 750 710 670 670 630 600 630 600 560 600 560 530 600 560 530 560 530 500 530 500 475
DIN 1729 K 20 1600 1500 1400 1320 1250 1250 1180 1120 1120 1120 1060 1000 1000 950 900 900 850 800 800 750 710 710 670 630 630 600 560

GERMANY
1) The values given are valid for a cut of up to 2.24 mm. For cuts of between 2.24 mm and 7.1 mm, reduce the values by 1 level (column) in row R10 - approximately 20%.
For cuts between 7.1 mm and 22.4 mm, reduce the values by 1 level in row R5 - approximately 40%.
2) The ϑc values have to be reduced by 30 .... 50 % when turning off casting crusts and skins or in the case of sand inclusions.
Page 51

3) The tool life τ for hard alloy P10, K10, K20 = 240 min, for high-speed steel SS = 60 min.
OPTIMUM Appendix turning

MASCHINEN - GERMANY

7 Appendix turning
Turning is a cutting manufacturing process with certain geometrically positive or negative cut-
ting edge geometries.
For the machining on the outside tool holder with quadrate shaft and for the machining on the
inside boring bars with rounded or oblated shafts are used (refer to ISO-code for tool holders
and boring bars).
To determine the machining direction, we distinguish between right, left and neutral tools.
On this type of lathes you generally work with right tools, as the tools are used before the center
of turning.

Machining direction for Machining direction for

tool holders boring bars

Fig.7-1: right holder Fig.7-2: right boring bar

Fig.7-3: left holder Fig.7-4: left boring bar

Fig.7-5: neutral holder

For the machining of a workpiece on the outer or inner diameter tools with dif-
ferent forms are required for longitudinal turning, facing, contour turning or
thread cutting as well as for grooving, cutting off and cutting.

Fig.7-6: tool holder for grooving, cutting Fig.7-7: boring bar for grooving
off and cutting
© 2009 GB

Page 52 Appendix turning Lathe D330x1000 ; Version 1.2 22 September 2009

Appendix turning
OPTIMUM
MASCHINEN - GERMANY

Fig.7-9: boring bar for thread cutting

Fig.7-8: tool holder for thread cutting

7.1 ISO-designation system for tool holder, inside machining

Material of the body Shank diameter Tool length Type of fixture

Identification Material Construction

letter of the body features

S steel cutter none

A with inner coolant
feeding
B with vibration clamped at the top
damping
D with vibration damping
and inner coolant
feeding
08
10
C hard metal none 12
cutter with 16
E steel head with inner coolant 20
feeding 25
F with vibration 32
clamped at the top
damping 40
50 above the hole
G with vibration
damping and inner
coolant feeding
Identification letters
H heavy metal none for the length
J with inner coolant
feeding A 32 mm
B 40 mm
clamped above the hole
C 50 mm
D 60 mm
E 70 mm
F 80 mm
G 90 mm
H 100 mm
J 110 mm
K 125 mm
L 140 mm
M 150 mm
N 160 mm
P 170 mm
Q 180 mm screwed through
R 200 mm the hole
S 250 mm
T 300 mm
U 350 mm
V 400 mm
W 450 mm
X special length
Y 500 mm
© 2009
GB

22 September 2009 Appendix turning Lathe D330x1000 ; Version 1.2 Page 53

OPTIMUM Appendix turning

MASCHINEN - GERMANY

7.2 ISO-designation system for tool holder, outside machining

Type of fixture Form of the indexable insert Form of the tool holder Free angle of the indexabl

clamped at the top

clamped at the top

above the hole

clamped above
the hole

screwed through
the hole

free angles where special

indications are requiired

© 2009 GB

Page 54 Appendix turning Lathe D330x1000 ; Version 1.2 22 September 2009

Appendix turning
OPTIMUM
MASCHINEN - GERMANY

7.3 Cutter with hard metal reversible carbide tip soldered on

Fig.7-10: straight cutter DIN 4971 Fig.7-11: bent cutter DIN 4972
ISO 1 ISO 2

Fig.7-12: inside tool DIN 4973 Fig.7-13: internal side turning tool for corner work
ISO 8 DIN 4974 ISO 9

Fig.7-14: tip of cutter DIN 4975 Fig.7-15: cutter width DIN 4976
ISO 4

Fig.7-16: offset face turning tool DIN 4977 Fig.7-17: offset tool for corner work DIN 4978
ISO 5 ISO 3

Fig.7-18: offset side turning tool DIN 4980 Fig.7-19: cuttoff tool DIN 4981
ISO 6 ISO 7

Lathe tools made of high-speed steel (HSS) and lathe tools with hard metal tips soldered on are
solid tools. The cutting edge geometry is to be ground for the corresponding machining.
“Grinding or regrinding of cutting edge geometries of turning tools“ on page 73
For tool holders with indexable inserts the cutter geometry of the tool holder and of the corre-
sponding indexable insert is given. For this type of tools there are four types of ficture for the
indexable inserts “ISO-designation system for tool holder, outside machining“ on page 54

7.4 Cut the first chips

In order to cut the first chips, a tool holder for the outside machining and a cutter bar for the
inside machining are required. Furthermore, some twist drills (HSS) are required to centrically
drill the part to be turned.
For the "do-it-yourselfer" it is recommended to use lathe tools with indexable inserts and scre-
wed clamping. The lathe tool does not require grinding and the indexable insert have a positive
cutting form level.
Before you can set the tools you have to determine the shank height and width respectively the
shank diameter.
The indicated height of centers is the measure from the cutting point to the lathe bed. As there is
no tool holder yet, the difference in height is to be determined from the bearing surface of the
tool holder in the quadraple holder to the rotation axis. For some machines, the difference in
height to the rotation axis is indicated in the technical data.
© 2009

For tools according to ISO or DIN, the shank height is equal to the height of the cutting point.
After clamping the tool holder, the height of the cutting point is to be checked. For drill rods
GB

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according to ISO, the height of the cutting point is half the shank diameter and for flattened drill
rods half the flattened height. For inside tools according to DIN the height of th cutting point cor-
responds to 0,8 x shank diameter respectively shank height.

ATTENTION!
If due to a variation in tolerance there is a slug or cone on the plane face, the exact height of
centers is to be found by facing trials (put the tool holder higher for slugs and lower for cones).
The height of centers is to be checked each time when the turning tools are changed!
For example, a shaft with a diameter of 30mm is to be machined of C45. The outside diameter is
to be turned and faced 20mm and a hole of 16mm is to be drilled.

Selecting the tools

• tool holder for turningand facing with 95° tool cutting edge angle
• indexable insert with a point angle of 80°
• we select a coated hard metal HC M15/K10 as cutting material. With this tool about 75% of
all lathe work on the outside diameter may be performed.

Selecting the cutting data

• A hard metal with the designation HC M15/K10 is selected as cutting material, cutting speed
ϑc = 80 m/min
• ap = 0,4mm for outside machining; ap = 0,2 mm for inside machining
• f = 0,05 mm/U (value for automatic feed)
The speed which is to be set is calculated with
the formular
ϑc × 1000 80 × 1000 –1
n = ------------------------- = ------------------------ = 849min
d × 3, 14 30 × 3, 14
© 2009 GB

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7.5 Outside machining, longitudinal turning and facing

For longitudinal turning, the tool holder is moved parallel to the rotation axis. The feed is perfor-
med by turning the handwheel of the top slide (therefore the bedslide is to be fixed with the
clamping screw). Furthermore you have to pay attention that the angular scale of the topslide is
set to zero so that no tapers are being produced.
The feed may also be performed automatically over the leading spindle by shifting the operating
lever of the leadscrew nut. Pay attention that the feed is not automatically switched off.
Switching off is to be done manually!
Pay also attention to the correct gear pairing!
The infeed of the depth of cut is performed over the handwheel of the compound slide in direc-
tion to the rotation axis.

feed direction

depth of cut infeed

Fig.7-20: longitudinal turning

For facing the bedslide is to be fixed with the clamping screw. The feed is performed by turning
the handwheel of the compound slide. The infeed of the depth of cut is performed with the hand-
wheel of the top slide.

depth of cut infeed

feed direction

Fig.7-21: facing

7.6 Inside machining, drilling and longitudinal turning

Selecting the tools
• drill chuck with morse cone seat
• twist drill with center drill
• drill rod with 95° tool cutting edge angle. This drill rod has a shank diameter of 8,0mm, e.g. a
cutting point height of 4,0mm. For a drill rod shank with a flattening at the top, a support may
be put beneath the tool in order to achieve the require height of centers. If the drill rod has
got a streight shank, a prison or a special streight shank seat is required.
• For drill rods please take into account that there is a predetermined minimum turning diame-
ter in this example of 11mm.
• The advantage in selecting these tools is that you may use the same indexable inserts as for
the outside machining. .
• With this tool you may perform about 75% of the lathe work on the inside diameter.
• In order to machine centric holes on the lathe, twist drills (HSS) are required. Furthermore a
drill chuck with a chucking capacity of 1 to 13mm or 3-16mm with a more cone seat (example
morse cone seat of the size 2) is required.
The drill chuck with the morse cone seat is held by the tailstock sleeve and the twist drills are
clamped into the drill chuck. The feed for drilling is performed after clamping the tailstock to
its position with the handwheel on the tailstock sleeve.
© 2009

• To make sure that the twist drill will not run off center when spot-drilling, the workpiece is to
be centered with a center drill. For holes from 6,0mm onward you should predrill with a smal-
GB

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ler drill. The drill diameter must be as large as the core diameter of the drill of the hole diame-
ter which is to be drilled! A 4,0mm and a 11,5mm drill are used.
• With the drill rod only the predetermined diameter is followed. The feed is performed by
turning the handwheel of the top slide paralell to the rotation axis (please also follow the indi-
cations for longitudinal turning. The infeed of the cutting depth is performed with the hand-
wheel of the compound slide in direction away from the center.
• Please make sure that the drill rods are clamped as short as possible (to avoid oscillations).
You may assure a projection length from the drill rod seat of 4 x drill hole diameter as an
empirical formula.

7.7 Tapping of external and internal threads

Threads with smaller diameters and standard thread pitches should be tapped manually on the
lathe with screw-taps or dies by turning the clamping chuck as this is more simple to produce.

ATTENTION !
Pull off the mains plug of the lathe if you want to tap a thread as described above.

Fig.7-22: die Fig.7-23: screw tap

Bolts and nuts with large thread diameters, deviating thread pitches or special types of thread,
right-handed and left-handed threads may be produced by threading. For this manufacturing
there are as well tool holders and drill rods with exchangeable indexable inserts (one-edged or
multiple-edged).

Fig.7-24: tap external thread Fig.7-25: tap internal thread

© 2009 GB

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7.7.1 Thread types

Designation Profile Code letter Short term (e. g.) Application

Machine tools and general mechanical engineering

Nut

M
M4x12
UN
UNC
ISO-thread 1/4" - 20UNC - 2A
UNF
Bolt UNEF
0,250 - UNC - 2A
UNS

Aircraft industry and aerospace

Nut

UNJ UNJ 1/4" - 20UNJ

Bolt

Cilindrical threads, pipe threads or conical pipe threads for connections which seal within the thread
Nut

Bolt

B.S.W.
Whitworth 1/4" in. -20 B.S.W.
W
© 2009
GB

22 September 2009 Appendix turning Lathe D330x1000 ; Version 1.2 Page 59

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Motion thread, leading spindle and transport spindle

Nut

ISO-trapezoid thread
Tr 40 x 7
(one- and multiple- Bolt TR
Tr 40 x 14 P7
threaded)

Fittings and for purposes of the fire brigade

Nut

Round thread Bolt RD RD DIN 405

Nut

Fittings and tube joints

NPT NPT 1“ – 11 ½“ NPT

Kegel

Bolt

© 2009 GB

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7.7.2 Metric thread (60° flank angle)

pitch P

Nut depth of thread of the bolt h2=0,6134 x P

depth of thread of the nut h1 = 0,5413 x P

rounding r = 0,1443 x P

flank diameter d2 = D2 =d - 0,6493

Bolt core removing hole drill = d - P

flank angle = 60°

Metric coarse-pitch thread

Sizes in mm: preferably use the threads in column 1
Denomination of thread Flank diameter

Core removing
Core diameter Depth of thread

Rounding r
d=D

hole drill
d2 = D2
Pitch P

Bolt Nut Bolt Nut

Column 1 Column 2
d3 D1 h3 H1

M1 0,25 0,838 0,693 0,729 0,153 0,135 0,036 0,75

M 1,1 0,25 0,938 0,793 0,829 0,153 0,135 0,036 0,85
M 1,2 0,25 1,038 0,893 0,929 0,153 0,135 0,036 0,95
M 1,4 0,3 1,205 1,032 1,075 0,184 0,162 0,043 1,1
M 1,6 0,35 1,373 1,171 1,221 0,215 0,189 0,051 1,3
M 1,8 0,35 1,573 1,371 1,421 0,215 0,189 0,051 1,5
M2 0,4 1,740 1,509 1,567 0,245 0,217 0,058 1,6
M 2,2 0,45 1,908 1,648 1,713 0,276 0,244 0,065 1,8
M 2,5 0,45 2,208 1,948 2,013 0,276 0,244 0,065 2,1
M3 0,5 2,675 2,387 2,459 0,307 0,271 0,072 2,5
M 3,5 0,6 3,110 2,764 2,850 0,368 0,325 0,087 2,9
M4 0,7 3,545 3,141 3,242 0,429 0,379 0,101 3,3
M5 0,8 4,480 4,019 4,134 0,491 0,433 0,115 4,2
M6 1 5,350 4,773 4,917 0,613 0,541 0,144 5,0
M8 1,25 7,188 6,466 6,647 0,767 0,677 0,180 6,8
M 10 1,5 9,026 8,160 8,376 0,920 0,812 0,217 8,5
M 12 1,75 10,863 9,853 10,106 1,074 0,947 0,253 10,2
M14 2 12,701 11,546 11,835 1,227 1,083 0,289 12
M 16 2 14,701 13,546 13,835 1,227 1,083 0,289 14
M18 2,5 16,376 14,933 15,294 1,534 1,353 0,361 15,5
M 20 2,5 18,376 16,933 17,294 1,534 1,353 0,361 17,5
M 22 2,5 20,376 18,933 19,294 1,534 1,353 0,361 19,5
M 24 3 22,051 20,319 20,752 1,840 1,624 0,433 21
M 27 3 25,051 23,319 23,752 1,840 1,624 0,433 24
M 30 3,5 27,727 25,706 26,211 2,147 1,894 0,505 26,5
M 36 4 33,402 31,093 31,670 2,454 2,165 0,577 32
M 42 4,5 39,077 36,479 37,129 2,760 2,436 0,650 37,5
M 48 5,5 44,752 41,866 41,866 3,067 2,706 0,722 43
M 56 5,5 52,428 49,252 49,252 3,374 2,977 0,794 50,5
M 64 6 60,103 56,639 56,639 3,681 3,248 0,866 58

Metric fine-pitch thread

Denomination of Flank Core
Flank diameter Core diameter Denomination
thread diameter diameter
d2 = D2 of thread d x P
dxP Bolt Nut d2 = D2 Bolt Nut
M2 x 0,2 1,870 1,755 1,783 M16 x 1,5 15,026 14,160 14,376
M2,5 x 0,25 2,338 2,193 2,229 M20 x 1 19,350 18,773 18,917
M3 x 0,35 2,773 2,571 2,621 M20 x 1,5 19,026 18,160 18,376
M4 x 0,5 3,675 3,387 3,459 M24 x 1,5 23,026 22,160 22,376
M5 x 0,5 4,675 4,387 4,459 M24 x 2 22,701 21,546 21,835
M6 x 0,75 5,513 5,080 5,188 M30 x 1,5 29,026 28,160 28,376
M8 x 0,75 7,513 7,080 7,188 M30 x 2 28,701 27,546 27,835
M8 x 1 7,350 6,773 6,917 M36 x 1,5 35,026 34,160 34,376
M10 x 0,75 9,513 9,080 9,188 M36 x 2 34,701 33,546 33,835
M10 x 1 9,350 8,773 8,917 M42 x 1,5 41,026 40,160 40,376
M12 x 1 11,350 10,773 10,917 M42 x 2 40,701 39,546 39,835
© 2009

M12 x 1,25 11,188 10,466 10,647 M46 x 1,5 47,026 46,160 46,376
M16 x 1 15,350 14,773 14,917 M48 x 2 46,701 45,546 45,835
GB

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7.7.3 British threads (55° flank angle)

BSW (Ww.): British Standard Withworth Coarse Thread Series is the most common coarse-pitch
thread in Great Britain and corresponds in its usage category to the metric coarse-pitch thread.
The designation of a hexagon head screw 1/4" - 20 BSW x 3/4" , is here: 1/4" is the nominal dia-
meter of the screw and 20 is the number of threads in 1" of length.
BSF: British Standard Fine Thread Series. BSW- and BSF are the thread selection for the com-
mon screws. This fine thread is very common in the British machine tool industry, but it is repla-
ced by the American UNF thread.
BSP (R): British Standard Pipe Thread. Cylindric pipe thread; designation in Germany: R 1/4"
(nominal width of the tube in inch). Tube threads are larger in their diameter as "BSW". Designa-
tion 1/8" - 28 BSP
BSPT: British Standard Pipe - Taper Thread. Conic tube thread, cone 1:16; designation: 1/4" - 19
BSPT
BA: British Association Standard Thread (47 1/2° flank angle). Common with instruments and
watches, is being replaced by the metric ISO thread and by the ISO miniature thread. It consists
of numeric designations from 25 to 0=6,0mm max diameter.

Table of the British threads

Nominal diameter of the Threads in 1" Threads in 1"
thread BSP/BSPT BA-threads
BSW BSF D.
(R) D. [mm] Nr.
Inch mm [mm]
55° Flank angle 47 1/2° Flank angle
1/16 1,588 60 - - 16 134 0,79
3/32 2,382 48 - - 15 121 0,9
1/8 3,175 40 - 28 9,73 14 110 1,0
5/32 3,970 32 - - - 13 102 1,2
3/16 4,763 24 32 - - 12 90,9 1,3
7/32 5,556 24 28 - - 11 87,9 1,5
1/4 6,350 20 26 19 13,16 10 72,6 1,7
9/32 7,142 20 26 - - 9 65,1 1,9
5/16 7,938 18 22 - - 8 59,1 2,2
3/8 9,525 16 20 19 16,66 7 52,9 2,5
7/16 11,113 14 18 - - 6 47,9 2,8
1/2 12,700 12 16 14 20,96 5 43,0 3,2
9/16 14,288 12 16 - - 4 38,5 3,6
5/8 15,875 11 14 14 22,91 3 34,8 4,1
11/16 17,463 11 14 - - 2 31,4 4,7
3/4 19,051 10 12 14 26,44 1 28,2 5,3
13/16 20,638 10 12 - - 0 25,3 6,0
7/8 22,226 9 11 14 30,20
15/16 23,813 9 11 - -
1" 25,401 8 10 11 33,25
1 1/8 28,576 7 9 - -
1 1/4 31,751 7 9 11 41,91
1 3/8 34,926 6 8 - -
1 1/2 38,101 6 8 11 47,80
1 5/8 41,277 5 8 - -
1 3/4 44,452 5 7 11 53,75
1 7/8 47,627 4 1/2 7 - -
2" 50,802 4 1/2 7 11 59,62
© 2009 GB

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7.7.4 Indexable inserts

For indexable inserts there are partial profile and full profile indexable inserts. The partial profile
indexable inserts are designed for a certain pitch range (e.g. 0,5 - 3mm).
• The partial profile indexable insert is optimally appropriate for the single-piece production.
• The full profile indexable insert is only designed for a certain pitch.

Fig.7-26: partial profile indexable insert Fig.7-27: full profile indexable insert

Determining the machining method of right-handed and left-handed threads:

Right-handed tool holders or drill rods are used. In order to top right-handed threads the feed
direction towards the clamping chuck is selected and the machine spindle turns to the right (the
turning direction of the machine spindle is determined when you look into the spindle from the
rear side). If a left-handed thread is to be tapped, the feed direction is selected away from the
clamping chuck in direction to the tailstock and the machine spindle turns to the right.

feed direction feed direction

Fig.7-28: right-handed thread with the machine Fig.7-29: left-handed thread with the machine
spindle turning to the right spindle turning to the right

As for thread cutting there are other conditions as for longitudinal turning, the forward cutter
must show a larger charance as the pitch angle of the thread.

Pitch angle ϕ
Pitch P
Thread diameter

P
tan ϕ = -----------------
D2 × π
Flank diameter
Core diameter

Fig.7-30: Pitch angle

© 2009
GB

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7.7.5 Examples for thread cutting

As an example, a metric external thread M30 x 1,0 mm made of brass is being machined.

Selecting the tool holder

For lathe D140 and D180, turning tool No.6 and for lathe D210, D240, D250, D280 turning tool
No.13.
Pointing turning tools are also appropriate ( „tip of cutter DIN 4975“ on page 55) with hard
metal plates soldered on of the complete set for the lathe D140 and D180, 8mm, 11-pieces, item
No. 344 1008 and for lathe D210, D240, D250, D280, 8mm, 11-pieces, item No. 344 1108 .
The above mentioned thread turning tools have a point angle of 60°.

Set of turning tools HM 8mm 344 1011

7-pieces with HM indexable inserts
TiN-coated in a wooden case
ISO designation tool holder
Turning tool 1: SWGCR/L0810D05
Turning tool 2: SCLCR/L0810D06
Turning tool 3: SDJCR/L0810D07
Turning tool 4: SDNCN/L0810D07
1 2 3 4 5 6 7
Turning tool 5: SCLCL0810D06
Turning tool 6: LW0810R/L 04
Turning tool 7: QA0812R/L03

Set of turning tools HM 10mm344 1111

7-pieces with HM indexable inserts
TiN-coated in a wooden case
ISO designation tool holder
Turning tool 8: SWGCR/L1010E05
Turning tool 9: SCLCR1010E06
Turning tool 10: SDJCR/L1010E07
Turning tool 11: SDNCN/L1010E07
Turning tool 12: SCLCR/L1010E06 8 9 10 11 12 13 14

Turning tool 13: LW1010R/L04

Turning tool 14: QA1012R/L03

Steel sheets are to be laid under the complete tool holder or turning tool to achieve exactly
the turning center.
The lowest spindle speed is set so that the lathe will not coast too long !
Mount gear pairing for pitch 1,0mm in the change gear !

The outer diameter had been turned to 30,0mm and the

tool holder is clamped in the quadraple holder for threa-
ding aligned angular to the rotation axis. The height of
centers is checked (as described).

Fig.7-31: Threading
© 2009 GB

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The depth of thread is manufactured in

various passes. The infeed is to be redu-
ced after each pass.
The first pass takes place with an infeed of
0,1 to 0,15mm.
For the last pass the infeed shall not be
below 0,04mm.
Fig.7-32: radial infeed For pitches up to 1,5mm the infeed may
be radial.
For our example 5 to 7 passes are being
determined.

For larger pitches the alternate flank

infeed is selected. The top slide is offset
alternately to the left and to the right by
0,05 to 0.10mm each. The last two pas-
ses are performed without lateral offset.
When the depth of thread is achieved, two
passes are performed without infeed.
Fig.7-33: alternate infeed To machine internal threads, about 2 pas-
ses shall be selected additionally for the
infeed (drill rods are more instable).

The cutting point is slit slightlym by turning the handwheel of the compound slide the scale is tur-
ned to zero. This is the point of departure for the infeed of the depth of thread.
The scale of the top slide is also set to zero (this is important for the lateral offset when turning
threads with larger pitches).
The cutting point is set just in front of the starting point of the start of the thread by actuating the
handwheel of the bedslide.
In standstill of the lathe a connection to the leadspindle is made by shifting the operating lever of
the lead-screw nut. With this connection, the adjusted thread pitch is transfered to the bedslide
and to the tool holder.

ATTENTION !
This connection must not be disconnected until the thread is finished !
© 2009
GB

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Starting the threading:

• Radial infeed over the handwheel of the compound slide.
• Turn the change-over, switch to the right.
• Start the machine and have the first cutting process run.

ATTENTION !
Always have the thumb ready on the OFF-switch in order to prevent a collision with the work-
piece or with the clamping chuck !
• Immediately turn off the machine at the runout of the thread and cam the cutter out by turning
the handwheel of the compound slide.
• Turn the change-over, switch to the left.
• Turn the machine on and return the bedslide to the starting point and switch the machine off.
• Radial infeed over the handwheel of the compound slide.
• Turn the change-over, switch to the right.
• Switch the machine on and have the second cutting process run.
• Repeat this proceedure as often as necessary until the depth of thread is achieved.
• To check the thread you may use a thread gauge or a workpiece with an internal thread M30
x 1,0.
• If the thread is having the exact size, the thread cutting process may be terminated. Now you
may again shift the operating lever of the lead-screw nut in standstill. In this way, the connec-
tion between the lead spindle and the bedslide is interrupted.
• Now the toothed wheels for the longitudinal feed are to be mounted again !

7.8 Recessing, cutting off and turning off

When recessing, grooves at the outer or inner diameter are manufactured e.g. for o-rings and
locking rings. There is also the possibility to manufacture recesses on the plane face.
When cutting off the finished workpiece is separated from the feed stock.
The turning off is a combination of recessing and longitudinal turning.
For each of these machining methods there are indexables inserts with sintered cutting form
levels available.

Fig.7-34: outside recessing Fig.7-35: recessing on plane faces

Fig.7-36: cutting off, turning off Fig.7-37: inside recessing

© 2009 GB

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Fig.7-38: recessing 1 Fig.7-39: recessing 2

On a shaft made of brass, an undercut for a thread M30 is to be machined. Groove with 5,0mm
with a depth of 2,5mm.
Selecting the tool holder: For lathe D140 and D180, turning tool No.7, and for lathe D210,
D240, D250, D280 turning tool No. 14
For small lathes the cutting speed for this machining compared to the cutting speed for longitudi-
nal turning is reduced by about 60% in order to prevent oscillations.
Cutting speed Vc = 40 m/min, the speed to be set would be 425min-1 .
The tool holder is clamped into the quadraple holder, aligned angular to the rotation axis and the
height of centers is checked.
The tool is positioned and fixed with the bedslide. The exact position is set with the handwheel
of the top slide. With the indexable insert the outer diameter is slit slightly (by turning the handw-
heel of the compound slide). Set the scale to zero and the first recess of 3,0mm width may be
machined. Apply some machine oil on the cutter to grease it! Another recess of 2,0mm is requi-
red to achieve a groove width of 5,0mm.
© 2009
GB

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7.9 Turning cones with high precision

D = large diameter [mm]

α⁄2 d = small diameter [mm]
L = cone length [mm]
α Lw = workpiece length [mm]
D

d
α = cone angle
α ⁄ 2 = setting angle
L Kv = cone proportion
Lw Vr = tailstock offset
Fig.7-40: designations on the cone
Vd = measure change [mm]
Vo = twist measure of
top slide [mm]

There are different possibilities to machine a cone on a common small lathe:

1. By twisting the top slide and by setting the setting-angle with the angular scale.
But there the graduation of the scale is too inaccurate. For chamfers and conic passings
the graduation of the angular scale is sufficient.
2. By a simple calculation, a stop measure of 100mm length (of your own production)
and a gauge with stand.

Calculation
of the offset of the topslide relating to the stop measure with a length of 100mm.

step by step

L -
Kv = ------------ Vd = 100mm
------------------- Vo = Vd
-------
D–d Kv 2

by one calculation step (summary)

× ( D – d )-
Vo = 100mm
------------------------------------------
2×L

example:
D = 30,0mm ; d = 24,0mm ; L = 22,0mm

100mm × ( 30mm – 24mm ) 100mm × 6mm

Vo = -------------------------------------------------------------------- = -------------------------------------- = 13, 63mm
2 × 22mm 44mm

The stop measure (100mm) is to be put between a fixed lunit stop and the bedslide. Put the
gauge with stand on the lathe bed and horizontally align the test prod with the testprod with the
topslide (90° to the topslide). The twisting measure is calculated with the above mentioned for-
mula. The topslide is twisted by this value (then set the gauge to zero). After removing the stop
© 2009 GB

measure, the bedslide will be aligned to the limit stop. The gauge must indicate the calculated

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value "Vo". Then the workpiece and the tool are clamped and positioned (the bedslide is fixed).
The infeed is performed with the handwheel of the topslide. The depth of cut is advanced with
the handwheel of the compound slide.

Gauge

n
directio
Infeed

Limit stop
Stop measure 100mm

Measuring direction Advance of depth of cut

Fig.7-41: Cone setting with stop measure

3. By measuring an existing cone with gauge and stand

The stand is put on the top slide. The gauge is aligned horizontally and 90° to the top slide. The
top slide is approximately adjusted to the cone angle and the test prod brought in contact with
the cone surface (fix the bedslide). Now the top slide is twisted in a way that the gauge does not
indicate any travel of the pointer over the whole length of the cone (offset over the handwheel of
the topslide).
Then you may start reaming the lathe as described under point 2. The workpiece might be a
flange for lathe chucks or a face plate.

Gauge

Mea
s
infee uring- an
d dir
ectio d
n

Advance of depth of cut

Fig.7-42: determining the cone with a gauge

© 2009

4. By offsetting the tailstock as the cone length is larger than the adjustable stroke of
the topslide.
GB

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The workpiece is clamped between two points, therefore center holes are required on the face.
They are to be drilled before removing the lathe chuck. The slaving of the workpiece is perfor-
med by a pulling pin and a lathe carrier.
The calculated value "Vr" is the offset measure of the tailstock. The offset is monitored with the
gauge (also the return travel). “designations on the cone“ on page 68
For this type of cone machining the lowest speed is used !
Annotation:
In order to check the position of the tailstock axis to the rotation axis, a shaft with two centerings
is clamped between the points. The stand with the gauge is put on the bedslide. The gauge is
aligned 90° to the rotation axis and horizontally brought into contact with the shaft. The gauge
will pass along the shaft with the bedslide. There must not be any travel of the pointer along the
whole length of the shaft. If a deviation is being shown, the tailstock is to be corrected.

Calculation:

Lw D–d
Vr = ---------------- or Vr = ------------- × Lw
2 × Kv 2×L

The tailstock offset must not exceed the value "Vrmax" as the workpiece
Vr max = Lw
-------- tumbles !
50

Example:
Kv = 1 : 40 ; Lw = 150mm ; L = 100mm

150 - = 1, 875mm 150

Vr = -------------- Vr max = --------- = 3mm
2 × 40 50

Fig.7-43: Workpiece between points: tailstock offset Vr

© 2009 GB

Page 70 Appendix turning Lathe D330x1000 ; Version 1.2 22 September 2009

Appendix turning
OPTIMUM
MASCHINEN - GERMANY

7.10 Cutting material

The basic requirement for a cutting material is that it is harder than the material which is to be
worked. The larger the difference is, the higher the wear resistance of the cutting material.

7.10.1 Cutting materials for chipping

High-speed steel (HSS)
High-speed steel is a high-alloy tol steel with high tenacy. The cutting edges may be ground
sharp-edged and the tools may be used with low cutting speed.

Hard metal (uncoated and coated)

Hard metal is a sintered material on the basis of tungsten carbide which may be applied for
almost all materials which are to be chipped due to the different composition. There are some
more wear-resistant types of hard metal and others with a higher tenacy.
The hard metals are divided into three main groups:
P - for long-chipping materials (steel, meltable cast iron)
M - for long- and short-chipping material (stainless steel, machining steel)
K - for short-chipping materials (castiron, NE metals, hardened steel)
An additional classification is performed with an annexed figure:
The lower the figure (P10), the higher is the wear resistance (planing)
The higher the figure (P40), the higher the tenacy (roughing).
In order to make hard metals more wear resistant, they may be coated with mechanically resi-
stant materials. These layers may be applied as single or multiple-layer coatings.
There are two proceedures:
• PVD / Physical Vapor Deposition,
• CVD / Chemikal Vapor Deposition.
The most common layers of mechanically resistant materials are:
• TiN / titanium nitride,
• TiC / titanium carbide,
• TiCN / titanium carbon nitride,
• Al2O3 / aluminum oxide,
as well as their combinations
The PVD-coated indexable inserts have sharper cutting edges and thus lower cutting forces.
Also well appropriate for small lathes.

Cermet (uncoated and coated)

Cermet (ceramic-metal) is a hard metal on the basis of titanium carbide. The cutting material
has very good wear resistance and edge strength. Indexable inserts made of Cermet are used
with high cutting speeds for planing.

Cutting ceramics
Cutting ceramics is composed of non-metalic anorganic material.
Oxide ceramics on the basis of aluminum oxide and an addition of zircon. The main application
is the machining of cast iron.
Mixed ceramics made of aluminum oxide an addition of titanium carbide has good a wear resi-
© 2009

stance on the edge strength. This cutting material is applied in the machining of chill casting.
GB

22 September 2009 Appendix turning Lathe D330x1000 ; Version 1.2 Page 71

OPTIMUM Appendix turning

MASCHINEN - GERMANY

Non-oxide ceramics on the basis of silicon nitride is insensible against thermal shock (it may be
used with coolants). Non-alloy cast iron is chipped.

Cubic boron nitride (CBN)

Cubic boron mitride has a high tenacy and a good high temperature strength. It is appropriate
for the planing of hardened materials.

Polycrystalline diamond (PKD)

Polycrystalline diamond has a good wear resistance. Good surface qualities with stable cutting
conditions are being achieved. Fields of application are nonferrous and non-metallic materials in
the finishing.
For other application references please refer to the documents of the tools’ manufacturer.

7.11 Standard values for cutting data when turning

The better the cutting data are selected, the better the turning result. Some standard values for
cutting speeds of different materials are listed on the following pages. “Cutting speed table“
on page 73

Criteria of the cutting conditions:

Cutting speed: Vc (m/min)
Depth of cut: ap (mm)
Infeed: f (mm/U)

Cutting speed:
In order to get the speed for the machine settings of the selected cutting speeds the following
formula is to be applied:

Vc × 1000-
n = ------------------------
d × 3, 14

Speed: n (1/min)
Workpiece diameter: d (mm)
For lathes without continuously adjustable drive (V-belt drive, speed gear) the nearest speed is
being selected.

Depth of cut:
In order to achieve a good chipping, the results of the depth of cut divided by the infed shall
result in a figure between 4 and 10.
Example: ap = 1,0mm; f = 0,14mm/U ; and this equals to in a value of 7,1 !

Infeed:
The infeed for roughing/turning is to be selected in a way that it does not exceed buff the value
of the corner radius.
Example: r = 0,4mm ; equals to fmax. = 0,2mm/U !
For planing/turning the infeed should be maximum 1/3 of the corner radius.
Example: r = 0,4mm ; equals to fmax. = 0,12mm/U !
© 2009 GB

Page 72 Appendix turning Lathe D330x1000 ; Version 1.2 22 September 2009

Appendix turning
OPTIMUM
MASCHINEN - GERMANY

7.11.1 Cutting speed table

Turning Drilling
Materials Cutting materials
HC
HC HC
HSS P10 P20 P40 K10 M15/ HSS
P40 K15
K10
non-alloyed steel; steel casting; 35 - 100 - 80 - 50 - - 70 - 150 - 90 - 30 -
C45; St37 - 50 - 150 - 120 - 100 - - 180 - 300 - 180 - 40
non-alloyed steel; steel casting; 20 - 80 - 60 - 40 - - 70 - 120 - 80 - 20 -
42CrMo4; 100Cr6 - 35 - 120 - 100 - 80 - - 160 - 250 - 160 - 30
high-alloyed steel; steel casting;
10 - 70 - 50 - - - 60 - 80 - 70 - 8-
X38CrMoV51;
- 20 - 110 - 90 - - - 130 - 220 - 140 - 15
S10-4-3-10
rust-resistant steel
- - - - 30 - - - 50 - 10 -
X5CrNi1810;
- - - - - 80 - - - 140 - 15
X10CrNiMoTi12
grey cast iron 15 - - - - 40 - - 90 - 70 - 20 -
GG10 ; GG40 - 40 - - - - 190 - - 200 - 150 - 30
cast iron with nodular graphite 10 - - - - 25 - - 80 - 60 - 15 -
GGG35 ; GGG70 - 25 - - - - 120 - - 180 - 130 - 25
40 - - - - 60 - - 90 - 60 - 30 -
copper, brass
- 90 - - - - 180 - - 300 - 150 - 80
40 - - - - 80 - - 100 - 80 - 40 -
aluminum alloys
- 100 - - - - 200 - - 400 - 200 - 80
Description of the coated hard metals:
HC P40 = a PVD - coating TiAlN
HC K15 = a CVD - coating TiN-Al2O3 - TiCN - TiN
HC M15/K10 = CVD - coating TiAiN

7.12 Grinding or regrinding of cutting edge geometries of turning tools

This affects all cutters made of high-speed steel (HSS) and tools with carbide tipped tools solde-
red on according to DIN 4971 - 4977 and 4980 - 4981.
The soldering steels may be used with the delivered edge polished section. But this is not the
optimum cutting edge geometry for all applications.
The HSS-square turned piece DIN 4964 type B are without a polished section, they are to be
ground before they are first used.
Special fused alumina for HSS and silicone carbide or diamonds for hard metal may be used as
grinding medium.
© 2009
GB

22 September 2009 Appendix turning Lathe D330x1000 ; Version 1.2 Page 73

OPTIMUM Appendix turning

MASCHINEN - GERMANY

7.12.1 Terms for the turning tool

f
Cutting direction

Chip thickness
Workpiece

Chip surface
ap
χn
Tool χ ε
Clearance surface ge
ed
W

Fig.7-44: Geometrically determined cutter for the Fig.7-45: Cut and chip size
separation process

Chip surface Chip surface

γ
γ Negative
chip angle
Positive chip a
β
Clearance β angle
Clearance
surface surface

α α
Positive clearance angle Positive clearance angle

Fig.7-46: Cut A - A, positive cutter Fig.7-47: Cut A - A, negative cutter

The following factors influence the chip

Wedge angle β
break when turning
Chip angle γ Setting angle χ
Clearance angle α Corner radius r
Clearance angle minor cutting edge αn Cutting edge geometry
Setting angle χ Cutting speed Vc
Setting angle minor cutting edge χn Depth of cut ap
Point angle ε Infeed f
Depth of cut ap (mm)
Infeed f (mm/U)

In most cases the setting angle is depending on the work piece. A setting angle of 45° to 75° is
suitable for roughing. A setting angle of 90° to 95° (no tendency to chattering) is suitable for pla-
ning.
The corner angle serves as passing from the major cutting edge to the minor cutting edge. Toge-
ther with the infeed it determines the surface quality. The corner radius must not be selected too
large as this might result in vibrations.
© 2009 GB

Page 74 Appendix turning Lathe D330x1000 ; Version 1.2 22 September 2009

Appendix turning
OPTIMUM
MASCHINEN - GERMANY

7.12.2 Cutting edge geometry for turning tools

High-speed steel Hard metal

Clearance Clearance
Chip angle Chip angle
angle angle
Steel +5° bis +7° +5° bis +6° +5° bis +11° +5° bis +7°
Cast non +5° bis +7° +5° bis +6° +5° bis +11° +5° bis +7°
NE - metal +5° bis +7° +6° bis +12° +5° bis +11° +5° bis +12°
Aluminum alloys +5° bis +7° +6° bis +24° +5° bis +11° +5° bis +24°

7.12.3 Types of cutting form levels

They are needed to influence the chip drain and the chip shape in order to achieve optimum
chipping conditions.

Examples of types of cutting form levels

b b
t
γ γ

Fig.7-48: cutting form level Fig.7-49: cutting form level with fillet

b = 1,0mm to 2,2mm b = 2,2mm with fillet

t = 0,4mm to 0,5mm
For infeeds of 0,05 to 0,5mm/U and depths of cut of 0,2mm to 3,0mm

The different apex angles of the cutting form level need to conduct the chip. ( j ) .

ϕ ϕ
Fig.7-50: Positive apex angle for planing Fig.7-51: Neutral apex angle for planing and
roughing

ϕ
© 2009

Fig.7-52: Negative apex angle for roughing

GB

22 September 2009 Appendix turning Lathe D330x1000 ; Version 1.2 Page 75

OPTIMUM Appendix turning

MASCHINEN - GERMANY

The ready-ground major cutting edge must be slightly ground with a grindstone for the pla-
ning.
For the roughing, a small chamfer must be produced with the grindstone in order to stabilize
the cutting edge against striking chips (bf = f x 0,8).

bf

10°

Fig.7-53: Stabilize cutting edge

Polished section for recessing and cutting off

(for chip angle refer to table)

1° 1°
γ

2°
2°
Fig.7-54: Polished section recessing and cutting off

Polished section for threading

The point angle or the shape for chasing tools is depending on the type of thread.
Also refer to:
• “Thread types“ on page 59
• “Pitch angle“ on page 63
The measure X must be larger than the depth of thread. Make save that no chip angle is being
ground as in this case there would be a strain of the profile.

X
ε

Fig.7-55: Polished section for threading

© 2009 GB

Page 76 Appendix turning Lathe D330x1000 ; Version 1.2 22 September 2009

Appendix turning
OPTIMUM
MASCHINEN - GERMANY

7.13 Lifetime and wear characteristics

In the chipping shaping by lifetime we understand the time which the cutting edge survives
(pure contact time).
The causes for the end of the lifetimes may be the following:
• dimensional deviation
• too high cutting pressure
• bad surface quality
• high burr formation for tool exit
The wear of clearance surface VB and the creater wear on the chipping surface is the most com-
mon type of tool wear. They are mainly formed by friction. The clearance surface wear has
effects on the dimensional accuracy of the workpieces and on the cutting force (the cutting force
increases by 10% for each 0,1mm VB).
The clearance wear is generally used as lifetime criteria.
Crackings on the cutting edge may be caused by casting crusts or forgeing skins. Another cause
may be ridge cracks (cracks transversal to the edge) which are caused by thermal and mecha-
nical shock louds such as interrupted cuts or short contact times for very hard cutting materials.
The cutting edge crack may be caused by selecting a too rough cutting material or by wrong sel-
ection for cutting data.
If a thermal excessive strain of the cutting material is existing, there would be a plastic deforma-
tion on the cutter.

KB

KT
VB

Fig.7-56: Clearance surface wear Fig.7-57: Creater wear

© 2009
GB

22 September 2009 Appendix turning Lathe D330x1000 ; Version 1.2 Page 77

OPTIMUM Maintenance

MASCHINEN - GERMANY

8 Maintenance
In this chapter you will find important information about
• inspection
• maintenance
• repair
of the lathe.
The diagram below shows which tasks fall under these headlines.

Maintenance

Inspection Maintenance Repair

Measuring Rough cleaning Mending

Testing Fine cleaning Replacing

Conserving Adjusting

Lubricating

Completing

Replacing

Re-adjusting

Illustr. 8-1: Maintenance – Definition according to DIN 31051

ATTENTION !
Properly-performed regular maintenance is an essential prerequisite for
• safe operation,
• fault-free operation,
• long service life of the lathe and
• the quality of the products to manufacture.
Installations and equipment from other manufacturers must also be in optimum condition.

ENVIRONMENTAL PROTECTION
During work on the spindle head and on the apron, please make sure that
• collector vessels are used with sufficient capacity for the amount of liquid to be col-
lected.
• liquid and oils are not split on the ground.
Clean-up any split liquid or oils immediately, using proper oil-absorption methods and dispose of
them in accordance with current legal requirements on the environment.

Cleaning-up spillages
Do not re-introduce liquids split outside the system during repair or as a result of leakage from
the reserve tank: collect them in a collecting vessel to be disposed of.

Disposal
© 2009 GB

Never dump oil or other polluant substances in water inlets, rivers or channels.

Page 78 Maintenance Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Maintenance
OPTIMUM
MASCHINEN - GERMANY

Used oils must be delivered to a collection centre. Consult your superior if you do not know
where the collection centre is.

8.1 Safety

WARNING!
The consequences of incorrect maintenance and repair work may include:
• very serious injury to personnel working on the lathe,
• damage to the lathe.
Only qualified personnel should carry out maintenance and repair work on the lathe.

8.1.1 Preparation

WARNING!
Only carry out work on the lathe if it has been switched off using the main switch and
secured by a padlock to prevent the lathe from being turned on again.
“Switching-off and securing the lathe“ on page 16
Attach a warning label.

8.1.2 Restarting
Run a safety check before restarting the lathe.
“Safety check“ on page 14

WARNING!
Before connecting the lathe, you must check that there is no danger for persons and that
the lathe is not damaged.

8.2 Inspection and maintenance

The type and extent of wear depends to a large scale on individual usage and service condi-
tions: For this reason, all the intervals are only valid for the authorized conditions.

Interval Where? What? How?

after each maintenance or repair operation

Lathe

“Safety check“ on page 14

Lubricate all slideways.

Lathe

lubricate Slightly lubricate the change gears with lithium-based

Start of work,

grease.
( Illustr.5-16: “change wheels“ on page 44)
Camlock clamp bolt
head spindle seat

control
“Fasten workpiece holder“ on page 39
fastening
© 2009
GB

22 / 09 / 2009 Maintenance Lathe D 330 x 1000 ; Version 1.2 Page 79

OPTIMUM Maintenance

MASCHINEN - GERMANY

Interval Where? What? How?

Excessive clearance in the slideways can be reduced by re-

adjusting the tapered gibs.
Turn the take-up screw clockwise. The tapered gib is
moved to the rear and reduces the clearance of the corre-
sponding slideway.

take-up screw
table saddle
as required

slideways

re-adjust

take-up screw
compound slide

take-up screw
top slide

Illustr. 8-2: take-up screws slideways

© 2009 GB

Page 80 Maintenance Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Maintenance
OPTIMUM
MASCHINEN - GERMANY

Interval Where? What? How?

Check the oil level in the inspection glass

• of the feed gear,
• of the apron,
• of the headstock.
It must at least reach the centre of the inspection glass.
“operating material“ on page 19.
after each maintenance or repair operation

apron inspection glass

feed gear / apron / headstock
Start of work,

visual inspection

headstock inspection glass

feed gear inspection glass

Illustr. 8-3: Oil-sight glasses

© 2009
GB

22 / 09 / 2009 Maintenance Lathe D 330 x 1000 ; Version 1.2 Page 81

OPTIMUM Maintenance

MASCHINEN - GERMANY

Interval Where? What? How?

Use an adequate collector vessel with sufficient capacity

for the oil change.
Unscrew the bolt of the outlet.
Unscrew the bolt of the charging hole.
Close the outlet when no more oil is running off.
Refill up to the reference mark in the centre of the inspec-
tion glass using a suitable funnel in the filling hole
“operating material“ on page 19
feed gear

oil change
feed gear charging hole
First after 200 hours in service, then once a year

feed gear outlet

Illustr. 8-4: Feed gear openings

apron charging hole

apron

oil change

apron outlet

Illustr. 8-5: apron openings

© 2009 GB

Page 82 Maintenance Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Maintenance
OPTIMUM
MASCHINEN - GERMANY

Interval Where? What? How?

headstock charging hole

First after 200 hours in service, then once a year

oil change

headstock outlet

Illustr. 8-6: headstock openings

Exhange of the V-belt set:

headstock

Disassemble the protective cover of the change gear

wheels and the motor cover.
Unfasten the fixing screw of the motor plate.
Lift the motor plate and unbend the V-belts in this .
Exchange the V-belt set.
Tighten the adjusting screws in a way that one single V-
belt may be squeezed approximately 5 mm.
as requiredf

control V-belt, fixing screw

tighten it

Illustr. 8-7: adjusting equipment V-belt

If required, retighten the V-belt set.

ATTENTION!
Only exchange the complete set of V-belts, never a single
one.
© 2009
GB

22 / 09 / 2009 Maintenance Lathe D 330 x 1000 ; Version 1.2 Page 83

OPTIMUM Maintenance

MASCHINEN - GERMANY

Interval Where? What? How?

Lubricate respectively fill in all lubricating nipples and oil-

cups with machinery oil.

lubricating nipples leading spindle

and feed rod

three lubricating nipples on the

compound slide
weekly

Lathe

lubricate

one lubricating nipple on the

top slide

four lubricating nipples on the

lathe saddle

two lubricating nipples on the

tailstock

Illustr. 8-8: lubricating nipple

© 2009 GB

Page 84 Maintenance Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Maintenance
OPTIMUM
MASCHINEN - GERMANY

Interval Where? What? How?

Lubricate respectively fill in all lubricating nipples and oil-

cups with machinery oil.

trip lever crossfeed / longitudinal

feed
weekly

Lathe

lubricate

Threading dial

Illustr. 8-9: lubricating nipple

8.3 Repair
For any repair work, request the assistance of an employee of Optimum Maschinen Germany
GmbH’s technical service or send us the lathe.
If the repairs are carried out by qualified technical staff, they must follow the indications given in
this manual.
Optimum Maschinen Germany GmbH does not take responsibility nor does it guarantee against
damage and operating malfunctions resulting from to observe this operating manual.
For repairs only use
• faultless and suitable tools,
• original parts or parts from series expressly authorized by Optimum Maschinen Germany
GmbH.
© 2009
GB

22 / 09 / 2009 Maintenance Lathe D 330 x 1000 ; Version 1.2 Page 85

OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

9 Ersatzteile - Spare parts - D330

9.1 Ersatzteilzeichnung Maschinenbett - Drawing spare parts machine bed

Abb.9-1: Maschinenbett - Machine bed

86 22.9.09

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Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

9.2 Ersatzteilzeichnung Maschinenunterbau - Drawing spare parts

machine substructure

Abb.9-2: Maschinenunterbau - Substructure

22.9.09 87
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OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

9.3 Ersatzteilzeichnung Antrieb, Spindelbremse, Abdeckungen -

Drawing spare parts actuation, spindle break, covers

Abb.9-3: Antrieb, Spindelbremse, Abdeckungen - Actuation, spindle break, covers

88 22.9.09

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Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

9.4 Ersatzteilzeichnung Steuerung - Drawing spare parts control

Abb.9-4: Steuerung - Control

22.9.09 89
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OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

9.5 Ersatzteilliste Maschinenbett, Maschinenunterbau, Antrieb,

Spindelbremse, Steuerung - Spare parts list machine bed, Actuation,
Spindle break, Control

Menge Grösse Artikelnummer

Pos.

Bezeichnung Designation Quan-

Size Article no.
tity
1 Befestigungsplatte Motor Motor plate 1 034010001
2 Maschinenbett Lathe bed 1 034010002
3 Bettbrücke Bed bridge 1 034010003
4 Sechskantschraube Hexagon screw 4 GB 5783-86 - M8x25
5 Innensechskantschraube Socket head screw 1 GB 70-85 - M10x40
6 Sechskantmutter Hexagon nut 1 DIN 4032 - M8
7 Kegelstift Taper pin 2 GB 881-86 - 8x60
8 Keilriemenscheibe Motor pulley 1 034010008
9 Innensechskantschraube Socket head screw 6 GB 70-85 - M12x60
10 Scheibe Washer 4 8
9-1 Scheibe Washer 6 12
9-2 Sechskantmutter Hexagon nut 6 DIN 4032-M12
11 Innensechskantschraube Socket head screw 8 GB 70-85 - M6x22
12 Zahnstange Rack 1 0340100012
13 Zylinderstift Straight pin 8 GB 117-86 - 6x28
14 Zahnstange Rack 3 0340100014
15 Sechskantschraube Hexagon screw 3 GB 5783-86 - M10x30
16 Leitspindel Lead screw 1 0340100016
17 Zugspindel Feed rod 1 0340100017
17-1 Buchse Bushing 1 03401000171
18 Schaltwelle Switching shaft 1 0340100018
19 Scheibe Washer 3 10
20 Sicherungsring Retaining ring 1 0340100020
21 Stift Pin 2 GB 879-86 - 3x25
22 Hülse Sleeve 1 0340100022
23 Passfeder Fitting key 1 0340100023
23-1 Spannstift Spring pin 2 GB 879-86 - 3 x 6
24 Keilriemen V-belt 1 0340100024
26 Innensechskantschraube Socket head screw 2 GB 70-85 - M6 x 20 0340100025
27 Sechskantmutter Hexagon nut 2 GB 41-86 - M 6
28 Gewindestift Grub screw 2 GB 78-85 - M6 x 20
29 Hebelbasis Collar 1 0340100029
30 Kegelstift Traper pin 2 GB 117-86/6x65
31 Stopfen Plug 1 0340100031
32 Innensechskantschraube Socket head screw 2 GB 70-85 - M8x55
33 Stopfen Plug 1 0340100033
34 Schmiernippel Lubrication cup 3 0340100034
36 Haltewinkel Bracket 1 0340100036
37 Buchse Bushing 1 0340100037
37-1 Feder Spring 1 03401000371
40 Schalthebel Lever 1 0340100040
41 Stehbolzen Bolt 1 0340100041
44 Stehbolzen Bolt 1 0340100044
45 Griff Handle 1 0340100045
46 Rändelmutter Knurled nut 2 0340100046
47 Schutzabdeckung Cover 1 0340100047
51 Innensechskantschraube Socket head screw 4 GB 70-86 - M4x10
52 Deckel Cover 1 0340100052
53 Spritzwand Splash guard 1 0340100053
55 Elektro Schaltkaste Electric box 1 0340100055
57 Antriebsmotor Driving motor 1 3x1,5kW/400V 50Hz 0340100057
58 Spänewanne Chip tray 1 0340100058
59 Innensechskantschrauben Socket head screw 16 GB 70-85 - M6 x 12
59-1 Scheibe Wascher 12 DIN 125 - A 6,4
61 Unterbau rechts Base right 1 0340100061
61-1 Tür rechts Door right 1 0313307
62-1 Tür links Door left 1 0313307
65 Verbindungswand Sheet metal plate 1 0340100065
65-1 Spänewanne Chip tray 1 03401000651

90 22.9.09

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Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

Menge Grösse Artikelnummer

Pos.

Bezeichnung Designation Quan-

Size Article no.
tity
72 Schloss Lock 2 0340100072
73 Rutschkupplung kpl. Friction clutch cpl. 1 0340100073CPL
83 Stange Rod 1 0340100083
84 Feder Spring 1 0340100084
85 Bolzen Bolt 1 0340100085
86 Hebel Lever 1 0340100086
88 Schraube Screw 1 0340100088
89 Sechskantmutter Hexagon nut 3 0340100089
93 Spanstift Spring pin 1 GB 879-86 - 5x40
94 Stange Rod 1 0340100094
95 Spanstift Spring pin 1 GB 879-86 - 5x26
96 Stange Rod 1 0340100096
97 Bremspedel Brake pedal 1 0340100097
98 Gewindestift Grub screw 2 GB80-85/M5x8
DIN 6885 - A 8 x 7 x
99 Passfeder Fitting key 1
40
100 Motor Motor 1 0343334
268 Zylinderstift Straight pin 2 GB 119-86 - C 5 x 16
269 Pin Stift 1 03401000256
270 Schaltergehäuse Switch housing 1 03401000270
271 Exzenter Eccentric 1 03401000271
272 Gewindestift Grub screw 1 GB 79-85 - M8x16
273 Schalter Switch 2 03401000273
274 Scheibe Washer 2 4
275 Schraube Screw 2 GB 823-88 - M4x40
276 Schraube Screw 4 GB 818-85 - M4x10
277 Deckel Cover 1 03401000277
278 Leitspindelabdeckung Lead screw cover 1 03401000278
279 Abdeckung Cover 1 03401000279
280 Gewindestift Grub screw 1 Gb 80-85 - M10x25
280-
Scheibe Washer 1
1
281 Bolzen Bolt 1 03401000281
282 Label Label 1 03401000282
282-
Niet Rivet 4
1
283 Splint Cotter pin 2 GB 81-96 - 2x12
284 Schalter Spindelbremse Switch spindle brake 1 03401000284
284-
Schalter Abdeckung Schalter cover 1 034010002841
1
285 Schraube Screw 2 GB 818-85 - M4x25
286 Schraube Screw 1 03401000286
287 Sechskantmutter Hexagon nut 1 DIN 4032 - M6
288 Buchse Bushing 1 03401000288
289 Gewindestift Grub screw 1 GB 80-85 - M8x6
290 Bolt Bolzen 1 03401000290
291 Hauptschalter Main switch 1 03401000291

22.9.09 91
Y:\Betriebsanleitungen\lathes\D330x1000\D330_parts\D330_parts.fm
OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

9.6 Ersatzteilzeichnung Getriebe Spindelstock 1-6 - Drawing spare parts

headstock gear 1-6

Abb.9-5: Getriebe Spindelstock 1-6 - Headstock gear 1-6

92 22.9.09

Y:\Betriebsanleitungen\lathes\D330x1000\D330_parts\D330_parts.fm
Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

9.7 Ersatzteilzeichnung Getriebe Spindelstock 2-6 - Drawing spare parts

headstock gear 2-6

Abb.9-6: Getriebe Spindelstock 2-6 - Headstock gear 2-6

22.9.09 93
Y:\Betriebsanleitungen\lathes\D330x1000\D330_parts\D330_parts.fm
OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

9.8 Ersatzteilzeichnung Getriebe Spindelstock 3-6 - Drawing spare parts

headstock gear 3-6

Abb.9-7: Getriebe Spindelstock 3-6 - Headstock gear 3-6

94 22.9.09

Y:\Betriebsanleitungen\lathes\D330x1000\D330_parts\D330_parts.fm
Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

9.9 Ersatzteilzeichnung Getriebe Spindelstock 4-6 - Drawing spare parts

headstock gear 4-6

Abb.9-8: Getriebe Spindelstock 4-6 - Headstock gear 4-6

22.9.09 95
Y:\Betriebsanleitungen\lathes\D330x1000\D330_parts\D330_parts.fm
OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

9.10 Ersatzteilzeichnung Getriebe Spindelstock 5-6 - Drawing spare parts

headstock gear 5-6

Abb.9-9: Getriebe Spindelstock 5-6 - Headstock gear 5-6

96 22.9.09

Y:\Betriebsanleitungen\lathes\D330x1000\D330_parts\D330_parts.fm
Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

9.11 Ersatzteilzeichnung Getriebe Spindelstock 6-6 - Drawing spare parts

headstock gear 6-6

Abb.9-10: Getriebe Spindelstock 6-6 - Headstock gear 6-6

22.9.09 97
Y:\Betriebsanleitungen\lathes\D330x1000\D330_parts\D330_parts.fm
OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

9.12 Ersatzteilliste Spindelstock - Spare parts list headstock

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Bezeichnung Designation Quan-

Size Article no.
tity
102 Innensechskantschraube Socket head screw 9 GB 70-85-M3x8
103-1 Kontrollleuchte Control light 1 034010001031
103-2 Momenttaster Rapid break 1 034010001032
103-3 Not-Aus Taster Emergency stop button 1 034010001033
104 Vorschubtabelle Feed table 1 03401000104
105 Abdeckplatte Cover plate 1 03401000105
106 Verschluss Closing 1 03401000106
107 Innensechskantschraube Socket head screw 6 GB 70-85 - M6 x 30
108 Ablassschraube Drain plug 1 03401000108
109 Gewindestift Grub screw 2 GB 80-85-M8x20
110 Verschlussschraube Plug screw 1 03401000110
111 Ablage Pad 1 03401000111
112 Deckel Spindelstock Cover 1 03401000112
113 Dichtung Gasket 1 03401000113
114 Innensechskantschraube Socket head screw 10 GB 70-85 - M6 x 16
115 Spannstift Spring pin 2 GB 879-86 - 5 x 30
116 Verschiebhebel Switching lever 1 03401000116
117 Gabel Fork 1 03401000117
DIN 3771 - 10,6 x 1,8 -
118 O-Ring O-Ring 2 03401000118
N - NBR 70
119 Welle Welle 1 03401000119
120 Zahnrad Gear 9 03401000120
121 Gehäuse Spindelstock Headstock housing 1 03401000121
122 Niet Rivet 1
123 Vorschubtabelle Feed table 1 03401000123
124 Verschiebgabel Switching fork 1 03401000124
125 Innensechskantschraube Socket head screw 2 GB 70-85 - M10 x 35
126 Ölschauglas Oil sight glass 1 03401000126
127 Verschiebblock Switching block 1 03401000127
128 Spannstift Spring pin 1 GB 879-86 - 4 x 18
129 Welle Shaft 1 03401000129
130 Innensechskantschraube Socket head screw 2 GB 70-85-M10x55
132 Stellring Set collar 1 03401000131
133 Senkkopfschraube Counter sunk screw 2 GB 819-85 - M4x8
137 O-Ring O-Ring 1 DIN 3771 - 7,5 x 1,8 03401000133
143 Frontdeckel Front cover 1 03401000143
145 Zahnradwelle Gear shaft 1 03401000145
146 Passfeder Fitting key 2 DIN 6885 - A 5 x 5 x 14 03401000146
147 Verschiebhebel Switching lever 1 03401000147
149 Verschiebgabel Switching fork 1 03401000149
150 Ring Ring 2 03401000150
151 O-Ring O-Ring 1 DIN 3771 - 25,8 x 3,55 03401000151
152 Buchse Bushing 2 03401000152
153 Hebel Lever 1 03401000153
154 Hebel Lever 1 03401000154
155 Hebel Lever 1 03401000155
156 Scheibe Washer 1 03401000156
157 Scheibe Washer 1
158 Nabe Driving collar 1 03401000158
159 Stahlkugel Steel ball 3 6mm 03401000159
165 Feder Spring 3 03401000165
166 Gewindestift Grub stift 5 GB 78-85 - M6 x 6 03401000166
167 Sicherungsring Retaining ring 2 DIN 472-42x1,75
168 Gewindestift Grub screw 1 GB 78-85-M8x12
169 Gewindestift Grub screw 1 GB 78-85-M8x8
170 Sicherungsring Retaining ring 1 DIN 471-30x1,5
171 Wellenzapfen Shaft bolt 1 03401000171
172 Spanstift Spring pin 1 GB 879-86/5x26
173 Platte Plate 1 03401000173
174 Hebelwelle Bremse Brake shaft 1 03401000174

98 22.9.09

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Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

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Bezeichnung Designation Quan-

Size Article no.
tity
175 Sicherungsring Retaining ring 1 DIN 471 - 12x1 03401000175
176 Flansch Flange 1 03401000176
177 Dichtung Gasket 1 03401000177
178 Dichtring Gasket 1 RWDR-25x40x10 03401000178
179 Kugellager Ball bearing 1 6005 03401000179
180 Keilriemenscheibe Pulley 1 03401000180
182 Scheibe Washer 1 03401000182
Spindelbremse Bremsba-
184 Brake pad 1 03401000184
cken
185 Sicherungsring Retaining ring 1 DIN 6799 - 8
186 Bolzen Bolt 1 03401000186
187 Innensechskantschraube Socket head screw 8 GB 70-85 - M6 x 16
188 Passfeder Fitting key 1 DIN 6885 - A 8 x 7 x 20 03401000188
189 Passfeder Fitting key 1 DIN 6885 - A 6 x 6 x 70 03401000189
190 Welle Shaft 1 03401000190
191 Passfeder Fitting key 1 DIN 6885 - A 5 x 5 x 50
192 Zahnrad Gear 1 03401000192
193 Zahnrad Gear 1 03401000193
194 Zahnrad Gear 1 03401000194
195 Sicherungsring Retaining ring 1 DIN 471 - 35x1,5 03401000195
196 Kugellager Bearing ring 1 6203 03401000196
197 Welle Shaft 1 03401000197
198 Gewindestift Grub screw 1 GB 80-85 - M8 x 16
199 O-Ring O-Ring 1 DIN 3771 - 34,5 x 3,55
200 Innensechskantschraube Socket head screw 3 GB 70-85 - M4 x 12
201 Blindflansch Cover 1 03401000201
202 Dichtung Gasket 1 03401000202
203 Kugellager Ball bearing 2 6204-2RSH 03401000203
204 Scheibe Washer 1 03401000204
205 Welle Shaft 1 03401000205
206 Passfeder Fitting key 2 DIN 6885 - A 8 x 7 x 56 03401000206
208 Zahnrad Gear 1 03401000208
209 Zahnrad Gear 1 03401000209
210 Welle Shaft 1 03401000210
211 Zahnrad Gear 1 03401000211
212 Zahnrad Gear 1 03401000212
213 Zahnrad Gear 1 03401000213
215 Abdeckkappe Cover 1 03401000215
216 O-Ring O-Ring 1 DIN 3771 - 42,5 x 5,3 03401000216
217 Zahnrad Gear 1 03401000217
221 Nutmutter Nut 2 03401000221
222 Ring Ring 1 03401000222
223 Flansch Flange 1 03401000223
224 Dichtung Gasket 1 03401000224
225 Innensechskantschraube Socket head screw 7 GB 70-85 - M6 x 25
226 Kegelrollenlager Taper roller bearing 1 30210 J2_Q 03401000226
227 Sicherungsring Retaining ring 1 DIN 471 - 50x2 03401000227
228 Zahnrad Gear 1 03401000228
229 Zahnrad Gear 1 03401000229
230 Passfeder Fitting key 1 DIN 6885 - A 8 x 7 x 18 03401000230
231 Zahnrad Gear 1 03401000231
232 Sicherungsring Retaining ring 1 DIN 471 - 72x2,5 03401000232
233 Kegelrollenlager Taper roller bearing 1 30212 J2_Q 03401000233
234 Dichtung Gasket 1 03401000234
235 Frontdeckel Cover 1 03401000235
236 Welle Shaft 1 03401000236
237 Passfeder Fitting key 1 DIN 6885 - A 6 x 6 x 40 03401000237
238 Passfeder Fitting key 1 DIN 6885 - A 8 x 7 x 80 03401000238
239 Bolt Bolt 3 03401000239
240 Stift Pin 3 03401000240
241 Feder Spring 3 03401000241
243 O-Ring O-Ring 1 DIN 3771 - 21,2 x 3,55 03401000243
244 Welle Shaft 1 03401000244

22.9.09 99
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OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

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Bezeichnung Designation Quan-

Size Article no.
tity
245 Sicherungring Retaining ring 3 DIN 471 - 20x1,2 03401000245
246 Kugellager Ball bearing 2 16004 03401000246
247 Zahnrad Gear 1 03401000247
251 Sechskantmutter Hexagon nut 1 GB 6172-86 - M12
252 Scheibe Washer 1 03401000252
253 Zahnrad Gear 1 03401000253
255 Dichtring Seal ring 1 03401000255
256 Welle Shaft 1 03401000256
257 Passfeder Fitting key 1 DIN 6885 - A 5 x 5 x 18 03401000257
258 Spannstift Spring pin 1 GB 879-86 - 3 x 10
259 Passfeder Fitting key 1 DIN 6885 - A 6 x 6 x 50 03401000259
260 Scheibe Washer 1 03401000260
261 Ring Ring 1 03401000261
262 Innensechskantschraube Socket head screw 3 GB 70-85 - M5 x 16
263 Flansch Flange 1
264 Dichtung Gasket 1
267 Zahnrad Gear 1
268 Innensechskantschraube Socket head screw 3 GB 70-85 - M8 x 35
269 Futterflansch (optional) Lathe chuck flange (optional) 1 3441512
270 Dreibackenfutter (optional) 3- jaw chuck (optional) 1 3440715
Spindelstock kpl. Headstock cpl 03401000121CPL

100 22.9.09

Y:\Betriebsanleitungen\lathes\D330x1000\D330_parts\D330_parts.fm
Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

9.13 Ersatzteilzeichnung Vorschubgetriebe 1-4 - Drawing spare parts feed gear

1-4

Abb.9-11: Vorschubgetriebe 1-4 - Feed gear 1-4

22.9.09 101
Y:\Betriebsanleitungen\lathes\D330x1000\D330_parts\D330_parts.fm
OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

9.14 Ersatzteilzeichnung Vorschubgetriebe 2-4 - Drawing spare parts

feed gear 2-4

Abb.9-12: Vorschubgetriebe 2-4 - Feed gear 2-4

102 22.9.09

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Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

9.15 Ersatzteilzeichnung Vorschubgetriebe 3-4 - Drawing spare parts

feed gear 3-4

Abb.9-13: Vorschubgetriebe 3-4 - Feed gear 3-4

22.9.09 103
Y:\Betriebsanleitungen\lathes\D330x1000\D330_parts\D330_parts.fm
OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

9.16 Ersatzteilzeichnungen Vorschubgetriebe 4-4 - Drawing spare parts

feed gear 4-4

Abb.9-14: Vorschubgetriebe 4-4 - Feed gear 4-4

104 22.9.09

Y:\Betriebsanleitungen\lathes\D330x1000\D330_parts\D330_parts.fm
Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

9.17 Ersatzteilzeichnung Wechselradgetriebe - Drawing spare parts

change wheel gear

Abb.9-15: Wechselradgetriebe - Change wheel gear

22.9.09 105
Y:\Betriebsanleitungen\lathes\D330x1000\D330_parts\D330_parts.fm
OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

Ersatzteile Vorschubgetriebe, Wechselradgetriebe - Spare parts list

feed gear, change wheel gear

Menge Grösse Artikelnummer

Pos.

Bezeichnung Designation Quan-

Size Article no.
tity
300 Senkkopfschraube Counter sunk screw 8 GB 819-85 - M4x8
301 Abdeckung Cover 1 03401000301
302 Abdeckung Cover 1 03401000302
303 Ölverschluss Oil plug 2 03401000303
304 Gehäuse Housing 1 03401000304
305 Innensechskantschraube Socket head screw 3 GB 70-85 - M8 x 70
306 Zylinderstift Straight pin 2 ISO 2338 - 6 x 30
307 Verschiebgabel Switching fork 2 03401000307
308 Hebel Lever 1 03401000308
310 Hebel Lever 1 03401000310
311 Spanstift Spring pin 1 GB 879-86 - 5x40
312 Welle Shaft 1 03401000312
313 O-Ring O-Ring 1 DIN 3771 - 25 x 2,65
314 Passfeder Fitting key 1 DIN 6885 - A 5 x 5 x 10
315 Hebelbasis Collar 1 03401000315
316 Hebel Lever 2 03401000316
317 Griff Handle 2 03401000317
318 Spanstift Spring pin 1 GB 879-86 - 5x50
319 Hebelbasis Collar 1 03401000319
321 Verschiebgabel Switching fork 1 03401000321
322 Sicherungsring Retaining ring 2 DIN 471 - 40x1,75
323 Verschiebgabel Switching fork 1 03401000323
324 Gewindestift Grub screw 4 GB 80-85 - M8 x 6
326 Stahlkugel Steel ball 4 6,5 03401000326
327 Dichtung Gasket 1 03401000327
328 Deckel Cover 1 03401000328
329 Innensechskantschraube Socket head screw 11 GB 70-85 - M6 x 20
330 O-Ring O-Ring 2 DIN 3771 - 34,5x2,65
331 Feder Spring 4 03401000331
332 Wahldrehgriff Select handle 1 03401000332
333 Wahldrehgriff Select handle 1 03401000333
334 Anzeige Indicator 2 03401000334
335 Innensechskantschraube Socket head screw 12 GB 70-85 - M3 x 8
351 Zahnrad Gear 1 03401000351
352 Sicherungsring Retaining ring 2 DIN 472 - 35x1,5
353 Kugellager Ball bearing 2 6003 03401000353
354 Scheibe Washer 1 GB 97.2-85 - 10
355 Sechskantmutter Hexagon nut 1 GB 6175-86 - M10
356 Innensechskantschraube Socket head screw 1 GB 70-85 - M8 x 35
359 Welle 1 03401000359
360 Wechselradaufnahme Change gear collar 1 03401000360
361 Scheibe Washer 2 03401000361
362 Sechskantmutter Hexagon nut 3 GB 6172-86 - M10
365 Gewindestange Threaded rod 1 M10 03401000365
366 Innensechskantschraube Socket head screw 1 GB 70-85 - M6 x 14
367 Scheibe Washer 1 03401000367
368 Zahnrad Gear 1 03401000368
381 Innensechskantschraube Socket head screw 13 GB 70-85 - M6 x 14
382 Lagerbock Bearing block 1 03401000382
383 Dichtung Gasket 1 03401000383
384 Passfeder Fittng key 2 DIN 6885 - A 5 x 5 x 14 03401000384
385 Welle Shaft 1 03401000385
386 Passfeder Fittng key 4 DIN 6885 - A 5 x 5 x 50 03401000386
387 Kugellager Ball bearing 2 6004 03401000387
388 Sicherungsring Retaining ring 2 DIN 471 - 20x1,2 03401000388
389 Zahnrad Gear 1 03401000389
390 Kugellager Ball bearing 6 6202 03401000390
391 Scheibe Washer 2 03401000391
393 Scheibe Washer 1 03401000393
394 Zahnrad Gear 2 03401000394

106 22.9.09

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Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

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Pos.

Bezeichnung Designation Quan-

Size Article no.
tity
395 Nutmutter Grooved nut 2 03401000395
396 Kugellager Ball bearing 2 51105 03401000396
397 Dichtung Gasket 1 03401000397
398 Lagerbock Bearing block 1 03401000398
399 Innensechskantschraube Socket head screw 11 GB 70-85 - M6 x 20 03401000399
400 Lagerdeckel Bearing cover 1 03401000400
401 Welle Shaft 1 03401000401
403 Deckel Cover 1 03401000403
404 Dichtung Gasket 1 03401000404
406 Welle Shaft 1 03401000406
408 Zahnrad Gear 1 03401000408
409 Zahnrad Gear 1 03401000409
410 Zahnrad Gear 1 03401000410
411 Scheibe Washer 1 03401000411
415 Scheibe Washer 1 03401000415
416 Zahnrad Washer 1 03401000416
417 Zahnrad Washer 3 03401000417
418 Zahnrad Washer 1 03401000418
419 Zahnrad Washer 1 03401000419
420 Sicherungsring Retaining ring 1 03401000420
421 Zahnrad Gear 1 03401000421
422 Dichtung Gasket 1 03401000422
424 Flansch Flange 1 03401000424
425 Ölschauglas Oil sigth glass 1 03401000425
426 Welle Shaft 1 03401000426
427 Innensechskantschraube Socket head screw 8 GB 70-85 - M4x10
428 Abdeckung Cover 1 03401000428
431 Innensechskantschraube Socket head screw 13
432 Deckel Cover 1 03401000432
433 Dichtung Gasket 1 03401000433
434 Kugellager Ball bearing 1 6302 03401000434
435 Zahnrad Gear 1 03401000435
436 Sicherungsring Retaining ring 2 DIN 471 - 20x1,2
438 Sicherungsring Retaining ring 2 DIN 471 - 22x1,2
439 Zahnrad Gear 2 03401000439
440 Welle Shaft 1 03401000440
441 Dichtung Gasket 1 03401000441
442 Deckel Cover 1 03401000442

22.9.09 107
Y:\Betriebsanleitungen\lathes\D330x1000\D330_parts\D330_parts.fm
OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

9.18 Ersatzteilzeichnung Schlosskasten 1-3 - Drawing spare parts apron 1-3

Abb.9-16: Schlosskasten 1-3 - Apron 1-3

108 22.9.09

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Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

9.19 Ersatzteilzeichnung Schlosskasten 2-3 - Drawing spare parts apron 2-3

Abb.9-17: Schlosskasten 2-3 - Apron 2-3

22.9.09 109
Y:\Betriebsanleitungen\lathes\D330x1000\D330_parts\D330_parts.fm
OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

9.20 Ersatzteilzeichnung Schlosskasten 3-3 - Drawing spare parts apron 3-3

Abb.9-18: Schlosskasten 3-3 - Apron 3-3

110 22.9.09

Y:\Betriebsanleitungen\lathes\D330x1000\D330_parts\D330_parts.fm
Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

9.21 Ersatzteilzeichnung Schlosskasten, Gewindeuhr - Drawing spare parts

apron, threading gauge

Abb.9-19: Gewindeuhr - Threading gauge

22.9.09 111
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OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

Ersatzteile Schlosskasten, Gewindeuhr - Spare parts list apron,

threading gauge

Menge Grösse Artikelnummer

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Bezeichnung Designation Quan-

Size Article no.
tity
451 Richtungsanzeige Scale 1 03401000451
452 Schloßmuttergehäuse Apron nut housing 1 03401000452
453 Schloßmutter Apron nut 1 03401000453
455 Gewindestift Grub screw 2 GB 80-85 - M6 x 10
456 Zahnradwelle Gear shaft 1 03401000456
457 Leiste Gib 1 03401000457
458 Sechskantmutter Hexagon nut 2 GB 6170-86 - M6
459 Innensechskantschraube Socket head screw 3 GB 70-85 - M5 x 16
460 Leiste Gib 1 03401000460
461 Gewindestift Grub screw 3 GB 80-85 - M5 x 16
462 Sechskantmutter Hexagon nut 3 GB 6170-86 - M5
463 Zylinderstift Straight pin 2 GB 119-86 - A 8 x 14 03401000463
464 Anzeige Scale 1 03401000464
465 Scheibe Washer 2 03401000465
466 Sicherungsring Retaining ring 2 DIN 471-32x1,5
467 Ölschauglas Oil glass 1 03401000467
468 Verschlussstopfen Oil plug 1 03401000468
470 Griff Handle 2 03401000470
471 Hebel Lever 1 03401000471
472 Gehäuse Schlosskasten Apron housing 1 03401000472
473 Gewindestift Grub screw 1 GB 879-86 - 5 x 32
474 Schaltwelle Switching shaft 1 03401000474
475 Aufnahme Schalthebel Collar 1 03401000475
476 Stahlkugel Steel ball 2 03401000476
477 Feder Spring 2 03401000477
478 Gewindestift Grub screw 1 GB 80-85 - M6 x 6 03401000478
481 Spannstift Spring pin 2 GB 879-86 - 5 x 20
482 Abdeckplatte Cover 1 03401000482
483 Gewindestift Grub screw 5 GB 70-85 - M6 x 12
484 Aufnahmeplatte Schalthebel Collar 1 03401000484
485 Gewindestift Grub screw 3 GB 70-85 - M6 x 35
486 Stopfen Plug 1 03401000486
487 Öler Oiler 3 8 03401000487
488 Schaltwelle Shaft 1 03401000488
489 Schalthebel Lever 1 03401000489
490 Schaltgriff Handle 2 03401000490
491 Stahlkugel Steel ball 2 03401000491
492 Feder Spring 2 03401000492
493 Gewindestift Grub screw 2 GB 78-85 - M6 x 6
494 Passfeder Key 1 03401000494
495 Getriebeschnecke Worm gear 1 03401000495
501 Passfeder Fitting key 1 DIN 6885 - A 5 x 5 x 18 03401000501
502 Ritzelwelle Gear shaft 1 03401000502
503 Lagerbock Bearing block 2 03401000503
504 Stift Pin 3 03401000504
505 Gewindestift Grub screw 3 GB 70-85 - M5 x 25
506 Gewindestift Grub screw 1 GB 80-85 - M6 x 8 03401000506
508 Befestigungsschraube Screw 1 03401000508
509 Griff Handle 1 03401000509
510 Innensechskantschraube Socket head screw 5 GB 70-85 - M6 x 12
511 Scheibe Washer 1 03401000511
512 Handrad Handwheel 1 03401000512
513 Ritzelwelle Gear shaft 1 03401000513
514 O-Ring O-Ring 1 DIN 3771-16x2,65
515 Spannstift Spring pin 2 GB 879-86 - 5 x 30
516 Sechskantschraube Hexagon nut 3 GB 5783-86 - M6 x 12
517 Scheibe Washer 1 03401000517
518 Zahnrad Gear 1 03401000518
519 Welle Shaft 1 03401000519
520 Spannstift Spring pin 2 GB 879-86 - 5 x 30

112 22.9.09

Y:\Betriebsanleitungen\lathes\D330x1000\D330_parts\D330_parts.fm
Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

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Bezeichnung Designation Quan-

Size Article no.
tity
521 Passfeder Fitting key 1 DIN 6885-A5x5x10
522 Zahnrad Gear 1 03401000522
523 Verschlusskappe Cap 1 03401000523
524 Welle Shaft 1 03401000524
525 Spannstift Spring pin 1 GB 879-86 - 3 x 24
526 Gewindestift Grub screw 2 GB 80-85 - M6 x 10
527 Buchse Sleeve 1 03401000527
528 Deckel Cover 1 03401000528
529 Zylinderstift Straight pin 3 GB 119-86 - A 5 x 24
531 Zahnrad Gear 1 03401000531
532 Stiftschraube Set screw 1 M6 x 6
533 Schaltgabel Switching fork 1 03401000533
534 Innensechskantschraube Socket head screw 2 GB 70-85 - M5 x 12 03401000534
535 Welle Shaft 1 03401000535
536 Zahnrad Gear 1 03401000536
537 Scheibe Washer 1 03401000537
538 Innensechskantschraube Socket head screw 1 GB 70-85 - M6 x 10
549 Anzeige Scale 1 03401000549
550 Gewindestift Grub screw 1 GB 80-85/M6x30
551 Öler OIler 3 03401000551
552 Welle Gewindeuhr Shaft 1 03401000552
553 Zahnrad Gewindeuhr Gear 1 03401000553
554 Distanzhülse Spacer 2 03401000554
555 Zahnrad Gewindeuhr Gear 1 03401000555
556 Sechskantmutter Hexagon nut 1 GB 6170-M6
557 Zahnrad Gewindeuhr Gear 1 03401000557
558 Sicherungsscheibe Retaining washer 1 GB 859-87 - 8 03401000558
559 Sechskantmutter Hexagon nut 1 GB 6170-86 - M8
560 Gehäuse Gewindeuhr Housing 1 03401000560
561 Niet Rivet 1 03401000561
562 Scheibe Washer 1 03401000562
563 Innensechskantschraube Socket head screw 1 GB 70-85 - M8 x 50
Schlosskasten kpl. Apron cpl. 03401000472CPL
Gewindeuhr kpl. Threading dial cpl. 03401000560CPL

22.9.09 113
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OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

9.22 Ersatzteilzeichnung Planschlitten - Drawing spare parts compound slide

Abb.9-20: Planschlitten - Compound slide

114 22.9.09

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Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

9.23 Ersatzteilzeichnung Oberschlitten - Drawing spare parts top slide

Abb.9-21: Oberschlitten - Top slide

22.9.09 115
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OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

Ersatzteile Planschlitten, Oberschlitten - Spare parts list compound slide,

top slide

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Bezeichnung Designation Quan-

Size Article no.
tity
601 Nutenstein Slot nut 2 03401000601
602 Hülse Bushing 1 03401000602
603 Innensechskantschraube Socket head screw 1 GB 70-85 - M8 x 16
604 Öler OIler 4 6mm 03401000604
605 Planschlitten Cross slide 1 03401000605
606 Nachstellschraube Keilleiste Adjusting screw 2 03401000606
607 Keilleiste Gib 1 03401000607
608 Gewindestift Grub screw 1 GB 77-85 - M6 x 12
609 Spannstift Feder pin 1 GB 879-86 - 3 x 16
610 Spindel Spindle 1 03401000610
611 Spindelmutter Spindle nut 1 03401000611
612 Gewindestift Grub screw 1 GB 80-85 - M6 x 16
613 Gewindestift Grub screw 1 GB 80-85 - M6 x 25
614 Schraube Screw 1 03401000614
615 Handrad Handwheel 1 03401000615
616 Stahlkugel Steel ball 2 03401000616
617 Feder Spring 2 03401000617
618 Skalenring Scale ring 1 03401000618
619 Innensechskantschraube Socket head screw 2 GB 70-86-M8x16
620 Führung Guide 1 03401000620
621 Rillenkugellager Ball bearing 1 51102 03401000621
622 Lagerbock Bearing block 1 03401000622
623 Gewindestift Grub screw 1 GB 77-85-N6x12
624 Innensechskantschraube Socket head screw 2 GB 70-85 - M6 x 25
625 Zahnrad Gear 1 03401000625
626 Bolzen Bolt 1 03401000626
627 Kurbelgriff Handle 1 03401000627
628 Passfeder Fitting key 1 A4x4x16
629 Schraube Screw 1 03401000629
630 Spannstift Spring pin 2 ISO 13337/6x50
631 Bettschlitten Bed slide 1 03401000631
632 Abdeckplatte Plate 1 03401000632
633 Schraube Screw 2 GB 823-88 - M8 x 12 03401000633
634 Öler Oiler 2 8mm 03401000634
635 Abstreifer Wiper 2 03401000635
636 Halter Abstreifer Holder 2 03401000636
637 Innensechskantschraube Socket head screw 4 GB 70-85-N8x40
638 Nachstellleiste Gib 2 03401000638
639 Führungsschiene Guide rail 1 03401000639
640 Führungsplatte Guide plate 1 03401000640
641 Sechskantschraube Hexagon screw 4 GB 5783-86 - M8 x 20
642 Führungsplatte Guide plate 1 03401000642
643 Abstreifer Wiper 2 03401000643
644 Halter Abstreifer Holder 1 03401000644
645 Schraube Screw 8 GB 823-88 - M4 x 12
646 Gewindestift Grub screw 4 GB 77-85 - M6 x 16
647 Sechskantmutter Hexagon nut 4 GB 6170-86 - M6
648 Sechskantschraube Hexagon screw 3 GB 5783-86 - M8 x 25
649 Verschraubung Fitting 1 03401000649
650 Gewindestift Grub screw 4 GB 77-85-M8x12
651 Halter Abstreifer Holder 1 03401000651
652 Klemmschraube Clamping screw 1 GB70-85/M8x60
655 Werkzeughalter Tool post 1 03401000655
656 Klemmschraube Clamping screw 8 GB 83-88 - M10 x 50 03401000656
657 Griffhalter Holder 1 M16 03401000657
658 Hebel Lever 1 M10x50 03401000658
659 Hebelgriff Handle 1 03401000659
660 Scheibe Washer 1 03401000660
661 Gewindebolzen Bolt 1 03401000661
663 Rastknopf Knob 1 03401000663

116 22.9.09

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MASCHINEN - GERMANY

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Bezeichnung Designation Quan-

Size Article no.
tity
664 Feder Spring 1 1x8x11 03401000664
665 Öler Oiler 1 8mm 03401000665
666 Spindel Spindle 1 03401000666
667 Spindelmutter Spindle nut 1 03401000667
668 Passfeder Fitting key 1 DIN 6885 - A 4 x 4 x 14 03401000668
669 Halterung Holder 1 03401000669
670 Rillenkugellager Ball bearing 1 51103 03401000670
671 Innensechskantschraube Socket head screw 2 GB 70-85 - M6 x 20
672 Skalenring Scale ring 1 03401000672
673 Stahlkugel Steel ball 2 03401000673
674 Feder Spring 2 0,7x5x9 03401000674
675 Kurbelgriff Handle 1 03401000675
676 Innensechskantschraube Socket head screw 1 GB 70-85 - M5 x 25 03401000676
677 Handrad Handwheel 1 03401000677
678 Justierkappe Screw 1 03401000678
680 Befestigungsschraube Screw 1 03401000680
681 Kurbelgriff Handle 1 03401000681
682 Gewindestift Grub screw 1 GB 80-85 - M6 x 16 03401000682
683 Unterteil Oberschlitten Top slide guide 1 03401000683
685 Stellschraube Keilleiste Adjusting screw 2 03401000685
686 Oberteil Oberschlitten Top slide 1 03401000686
687 Keilleiste Gib 1 03401000687
Oberschlitten kpl. Top slide cpl. 03401000686CPL
Stahlhalter kpl. Tool post cpl. 03401000655CPL

22.9.09 117
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OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

9.24 Ersatzteilzeichnung Reitstock - Drawing spare parts tailstock

Abb.9-22: Reitstock - Tailstock

118 22.9.09

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Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

9.24.1 Ersatzteile Reitstock - Spare parts list tailstock

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Bezeichnung Designation Quan-

Size Article no.
tity
701 Spindelmutter Spindle nut 1 03401000701
702 Gewindestift Grub screw 2 GB 70-85 - M5 x 16
703 Spindel Spindle 1 03401000703
704 Passfeder Fitting key 1 DIN 6885 - A 5 x 5 x 20 03401000704
705 Kugellager Ball bearing 2 51102 0343319
706 Lagerbock Bearing block 1 03401000706
707 Innensechskantschraube Socket head screw 4 GB 70-85 - M5 x 20
708 Gewindestift Grub screw 1 GB 818-85 - M4 x 5
709 Öler Oiler 3 6mm 03401000709
710 Skalenring Scale ring 1 03401000710
711 Griff Handle 1 03401000711
712 Klemmhebel Lever 1 03401000712
713 Scheibe Washer 1 03401000713
714 Griff Handle 1 03401000714
715 Befestigungsschraube Griff Screw 1 03401000715
716 Handrad Handwheel 1 03401000716
717 Justierschraube Screw 1 03401000717
718 Innensechskantschraube Grub screw 1 GB 78-85 - M5 x 20
719 Welle Shaft 1 03401000719
720 Schraube Screw 2 03401000720
721 Innensechskantschraube Grub screw 2 GB 78-85 - M12 x 45
722 Innensechskantschraube Grub screw 1 GB 78-85 - M12 x 50
723 Pinole Pinole 1 03401000723
724 Reitstockkörper Housing 1 03401000724
725 Gewindestift Grub screw 1 GB 80-85 - M6 x 6
726 Niet Rivet 4
727 Exzenter Excenter 1 03401000727
728 Griff Handle 2 03401000728
729 Hebel Lever 1 03401000729
730 Welle Shaft 1 03401000730
731 Exzenter Excenter 1 03401000731
732 Gewindestift Grub screw 1 GB 879-86 - 5 x 24 03401000732
733 Scheibe Washer 1 03401000733
736 Führungsgrundplatte Guide plate 1 03401000736
737 Klemmplatte Maschinenbett Clamping plate 1 03401000737
738 Skala oben Scale top 1 03401000738
739 Skala unten Scale under 1 03401000739
740 Rastbolzen Locking bolt 1 03401000740
741 Feste Zentrierspitze Steady centers 2 03401000741
742 Skala Reitstock Scale tailstock 1 03401000742
743 Aufnahme Collet 1 03401000743
744 Feder Spring 1 03401000744
745 Scheibe Washer 1 03401000745
746 Scheibe Washer 1 03401000746
747 Sechskantschraube Hexagon screw 1 GB 5782-86 - M6x35
748 Sechskantschraube Hexagon screw 1 GB 5782-86 - M16x100
749 Sechskantschraube Hexagon screw 4 GB 823-88 - M4 x 12
750 Halter Abstreifer Holder wiper 1 03401000750
751 Abstreifer Wiper 1 03401000751
752 Halter Abstreifer Holder wiper 1 03401000752
753 Abstreifer Wiper 1 03401000753
754 Federblech Spring sheet 1 03401000754
Reitstock kpl. Tailstock cpl. 03401000724CPL

22.9.09 119
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OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

9.25 Ersatzteilzeichnung feststehehde Lünette - Drawing spare parts steady rest

Abb.9-23: Feststehende Lünette - Steady rest

120 22.9.09

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Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

9.25.1 Ersatzteile Feststehende Lünette - Spare parts steady rest

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Bezeichnung Designation Quan-

Size Article no.
tity
801 Rändelgriff Knurled handle 3 03401000801
802 Zylinderstift Straight pin 3 GB 119-86 - C 3 x 18 03401000802
803 Überwurfmutter Nut 3 03401000803
804 Gewindestange Threaded rod 3 03401000804
805 Zentrierhülse Centering bushing 3 03401000805
806 Endstück End piece 3 03401000806
807 Mutter Nut 1 03401000807
feststehende Lünette Ober-
808 Steady rest upper section 1 03401000808
teil
809 Sechskantmutter Hexagon nut 4 GB 6170-86 - M6 03401000809
810 Gewindestift Grub screw 3 GB 79-85 - M6 x 16 03401000810
812 Schraube Screw 1 03401000812
813 Gewindebolzen Threaded bolt 1 03401000813
814 Spannstift Spring pin 1 GB 879-86 - 5 x 24 03401000814
feststehende Lünette Unter-
815 Follow rest lower part 1 03401000815
teil
816 Sechskantmutter Hexagon nut 1 03401000816
817 Scheibe Washer 1 DIN 125 - A 13 03401000817
818 Gewindestift Grub screw 3 GB 78-85 - M6 x 6 03401000818
819 Klemmplatte Clamping plate 1 03401000819
820 Klemmschraube Clamping screw 1 GB 37-88 - M12x90 03401000820
feststehende Lünette kom-
0 Steady rest complete 03401000815CPL
plett

22.9.09 121
Y:\Betriebsanleitungen\lathes\D330x1000\D330_parts\D330_parts.fm
OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

9.26 Ersatzteilzeichnung mitlaufende Lünette - Drawing spare parts follow rest

Abb.9-24: Mitlaufende Lünette - Follow rest

9.26.1 Ersatzteile mitlaufende Lünette - Spare parts follow rest

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Bezeichnung Designation Quan-

Size Article no.
tity
826 Rändelgriff Knurled handle 2 03401000826
827 Gewindestift Grub Screw 2 GB 119-86 - C 3 x 18 03401000827
828 Überwurfmutter Sleeve nut 2 03401000828
829 Gewindestange Threaded rod 2 03401000829
830 Zentrierhülse Centering bushing 2 03401000830
831 Endstück End piece 2 03401000831
832 Gewindestift Grub Screw 2 GB 78-85 - M6 x 6 03401000832
833 Sechskantmutter Hexagon nut 2 GB 6170-86 - M6 03401000833
834 Gewindestift Grub screw 2 GB 79-85 - M6 x 16 03401000834
835 Körper mitlaufende Lünette Body follow rest 1 03401000835
836 Innensechskantschraube Socket head screw 2 GB 70-85 - M8 x 45 03401000836
0 mitlaufende Lünette komplett Follow rest complete 1 03401000835CPL

122 22.9.09

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Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

9.27 Ersatzteilzeichnung Drehfutterschutz - Drawing spare parts

chuck protection

Abb.9-25: Drehfutterschtz - Chuch protection

9.27.1 Ersatzteile Drehfutterschutz - Spare parts chuck protection

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Bezeichnung Designation Quan-

Size Article no.
tity
837 Platte Plate 1 C0632_F06_01 03401000837
838 Innensechskantschraube Socket head screw 4 GB 70-85 - M8 x 20
839 Gewindestift Grub screw 1 GB 78-85 - M6 x 8
840 Exzenter Eccentric 1 03401000840
841 Schraube Screw 2 GB 823-88 - M4 x 25
842 Schalter Switch 1 03401000842
843 Abdeckung Cover 1 03401000843
844 Gewindestift Grub screw 1 GB 79-85 - M8 x 12
845 Welle Shaft 03401000845
846 Innensechskantschraube Socket head screw 4 GB 70-85 - M6 x 35
847 Schutzabdeckung Protection cover 1 03401000847
848 Griff Handle 1 03401000848
849 Gewindestift Grub screw 2 GB 70-85 - M6 x 12
850 Gewindestift Grub screw 1 GB 78-85 - M5 x 6
851 Spannstift Spring pin 1 GB 879-86 - 5 x 32
Drefutterschutz kpl. Chuck protection cpl. 03401000847CPL

22.9.09 123
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OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

9.28 Ersatzteilzeichnung Spanschutz - Drawing spare parts

chip protection D330x1000

Abb.9-26: Spanschutz - Chip protection D330x1000

9.29 Ersatzteilzeichnung Spanschutz - Drawing spare parts

chip protection D330x1000 DPA

Abb.9-27: Spanschutz - Chip protection D330x1000 DPA

124 22.9.09

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MASCHINEN - GERMANY

9.29.1 Ersatzteile Spanschutz - Spare parts chip protection

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Bezeichnung Designation Quan-

Size Article no.
tity
852 Schraube Screw 2 GB 819-85 - M6x16 03401000852
853 Halter Holder 1 Träger 03401000853
854 Innensechskantschraube Socket head screw 2 GB 70-85 - M6 x 12 03401000854
855 Welle Shaft 1 Welle 03401000855
856 Sechskantbuchse Hexagon bushing 1 Sechskant 03401000856
857 Sechskantmuttern Hexagon nut 1 GB 6170-86 - M4 03401000857
858 Gewindestift Grub screw 1 GB 78-85 - M4 x 10 03401000858
859 Schutzabdeckung Protection cover 1 Schutzschild 03401000859
860 Scheibe Washer 2 DIN 125 - A 5,3 03401000860
861 Innensechskantschraube Socket head screw 2 GB 70-85 - M5 x 8 03401000861
Spanschutz D330x1000 kpl. Chip protection D330x1000 cpl. 03401000859CPL
872 Schutzabdeckung Protection cover 1 03401000872
873 Innensechskantschraube Socket head screw 2 GB 70-85 - M5 x 10
874 Scheibe Washer 2 DIN 125 - A 5,3
875 Halter Holder 1 03401000875
876 Innensechskantschraube Socket head screw 2 GB 70-85 - M6 x 20
877 Scheibe Washer 2 DIN 125 - A 6,4
Spanschutz D330x1000DPA Chip protection D330x1000DPA
03401000872CPL
kpl. cpl.

22.9.09 125
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OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

9.30 Ersatzteilzeichnung Maschinenlampe - Drawing spare parts machine lamp

Abb.9-28: Maschinenlampe - Machine lamp

9.30.1 Ersatzteile Maschinenlampe - Spare parts machine lamp

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Bezeichnung Designation Quan-

Size Article no.
tity
862 Federring Spring ring 1 03401000862
863 Glasscheibe Glas plate 1 03401000863
864 Lampe Lamp 1 03401000864
865 Reflektor Reflector 1 03401000865
866 Gehäuse Housing 1 03401000866
867 Führung Guide 1 03401000867
868 Innensechskantschraube Socket head screw 3 GB 70-85 - M5 x 20 03401000868
869 Aufnahme Collet 1 03401000869
870 Innensechskantschraube Socket head screw 2 GB 70-85 - M6 x 20 03401000870
871 Grundplatte Ground plate 1 03401000871
Maschinenleuchte kpl. Machine lamp cpl. 03401000866CPL

126 22.9.09

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Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

9.31 Ersatzteilzeichnung D330x1000 DPA, DPA2000, Messleisten - Spare parts

drawing D330x1000 DPA, DPA2000, measuring gib

Abb.9-29: DPA2000, Messleisten - DPA2000, measuring gib

9.31.1 Ersatzteile DPA2000, Messleisten - Spare parts DPA2000, measuring gib

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Bezeichnung Designation Quan-

Size Article no.
tity
878 DPA2000 DPA2000 1 03401000878
879 Abdeckung Cover 1 03401000879
880 Platte Plate 1 03401000880
881 Messleiste Oberschlitten Measuring gib top slide 1 03401000881
882 Abdekung Cover 1 03401000882
883 Messleiste Bettschlitten Measuring gib lathe saddle 1 03401000883
884 Halter Holder 1 03401000884
885 Platte Plate 1 03401000885
886 Abdeckung Cover 1 03401000886
887 Messleiste Planschlitten Measuring gib cross slide 1 03401000887

22.9.09 127
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OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

9.32 Schaltplan - Wiring diagram D330x1000

Abb.9-30: Schaltplan - Wiring diagram D330x1000

128 22.9.09

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Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

9.32.1 Ersatzteilliste Elektrik - Spare parts list electrical components D330x1000

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Bezeichnung Designation Quan-

Size Article no.
tity
1F1 Sicherung Fuse 1 034010001F1
1F2 Sicherung Fuse 1 034010001F2
1F3 Sicherung Fuse 1 034010001F3
1K1 Motorschütz Motor contactor 1 034010001K1
1K2 Motorschütz Motor contactor 1 034010001K2
1K3 Motorschütz Motor contactor 1 034010001K3
1K4 Relais Relay 1 034010001K4
1S1 Not-Aus-Schalter Emergency stop button 1 034010001S1
1S4 Schalter Abdeckung Cover safety switch 1 034010001S4
1S5 Schalter Drehfutterschtz Lathe chuck safety switch 1 034010001S5
Schalter Maschinenbeleuch-
1S7 Work light switch 1 034010001S7
tung
1S8 Hauptschalter Main switch 1 034010001S8
Drehrichtungsschalter Links-
1S10 Change-over switch reverse 1 034010001S10
lauf
Drehrichtungsschalter
1S11 Change-over switch forward 1 034010001S11
Rechtslauf
1S12 Schalter Spindelbremse Switch spindle breack 1 034010001S12
1S13 Momenttaster Direct run 1 034010001S13
1H1 Maschinenbeleuchtung Machine light 1 034010001H1
1H6 Betriebskontorllleuchte Control light operating 1 034010001H6
1T1 Transformator Transformer 1 0340100011T1
1M1 Antriebsmotor Driving motor 1 0340100011M1

22.9.09 129
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OPTIMUM Ersatzteile - Spare parts - D330
MASCHINEN - GERMANY

9.33 Schaltplan - Wiring diagram D330x1000 Vario

Abb.9-31: Schaltplan - Wiring diagram D330x1000 Vario

130 22.9.09

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Ersatzteile - Spare parts - D330 OPTIMUM
MASCHINEN - GERMANY

9.33.1 Ersatzteilliste Elektrik - Spare parts list electrical components D330x1000 Vario

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Pos.

Bezeichnung Designation Quan-

Size Article no.
tity
1F1 Sicherung Fuse 1 034010001F1
1F2 Sicherung Fuse 1 034010001F2
1F3 Sicherung Fuse 1 034010001F3
1K1 Motorschütz Motor contactor 1 034010001K1
1K2 Motorschütz Motor contactor 1 034010001K2
1K3 Motorschütz Motor contactor 1 034010001K3
1K4 Relais Relay 1 034010001K4
1S1 Not-Aus-Schalter Emergency stop button 1 034010001S1
1S4 Schalter Abdeckung Cover safety switch 1 034010001S4
1S5 Schalter Drehfutterschtz Lathe chuck safety switch 1 034010001S5
Schalter Maschinenbeleuch-
1S7 Work light switch 1 034010001S7
tung
1S8 Hauptschalter Main switch 1 034010001S8
Drehrichtungsschalter Links-
1S10 Change-over switch reverse 1 034010001S10
lauf
Drehrichtungsschalter
1S11 Change-over switch forward 1 034010001S11
Rechtslauf
1S12 Schalter Spindelbremse Switch spindle breack 1 034010001S12
1S13 Momenttaster Direct run 1 034010001S13
1H1 Maschinenbeleuchtung Machine light 1 034010001H1
1H6 Betriebskontorllleuchte Control light operating 1 034010001H6
1T1 Transformator Transformer 1 0340100011T1
1M1 Antriebsmotor Driving motor 1 0340100011M1
1Q1 Frequenzumrichter Frequency conventer 1 0340100011Q1

22.9.09 131
Y:\Betriebsanleitungen\lathes\D330x1000\D330_parts\D330_parts.fm
OPTIMUM Malfunction

MASCHINEN - GERMANY

10 Malfunction

Cause/
Malfunction Solution
possible effects

The lathe does not start. • The position switch of the spindle • Check and adjust the position
break switches the lathe off. switch of the spindle brake.
• The position switch of the lathe • Check and adjust the position
chuck switches the lathe off. switch of the lathe chuck protec-
• The position switch of the protec- tion.
tion cover on the headstock swit- • Check and adjust the position
ches the lathe off. switch of the protection cover on
• ERMERGENCY-STOP actuated. the headstock.
• Unclamp the EMERGENCY-STOP.
• “Wiring diagram“ on page 104

The control lamp for oper- • fuse FU 2 is defective • replace fuse

ation is not on • control transformer is defective • replace transformer
• control lamp for operation is defec- • replace control lamp for operation
tive • replace fuse FU 1

• fuse FU 1 is defective

The machine lighting is • fuse FU 3 is defective • replace fuse

not on • control transformer is defective • replace transformer

Motor is humming • fuse is defective • replace fuse

Surface of workpiece too • tool blunt • resharpen tool

rough • tool springs • clamp tool wit less overhang
• feed too high • reduce feed
• radius at the tool tip too little • increase radius

V-belts squeak and slip. • V-belts defective, used “control V-belt, tighten it“ on
• tension of V-belts is too low page 83

Workpiece is becoming • centres are not aligned (tailstock • adjust tailstock to the centre
cone has offset)
• top slide not well aligned (cutting • well align top slide
with the top slide)

Lathe is chattering • feed too high • reduce feed

• main bearings have clearance • have the main bearing re-adjusted

Centre runs hot • workpiece has expanded • loosen tailstock tip

Tool has a short edge life • cutting speed too high • reduce cutting speed
• lower crossfeed/smooth finish
• crossfeed too high (allowance not over 0,5 mm)
• more coolant
• insufficient cooling

Flank wear too high • clearance angle too small (tool • increase clearance angle
"pushes")
• tool tip not adjusted to centre • correct height adjustment of the
height tool
© 2009 GB

Page 132 Malfunction Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Malfunction
OPTIMUM
MASCHINEN - GERMANY

Cause/
Malfunction Solution
possible effects

Cutting edge breaks off • wedge angle too small (heat build- • increase wedge angle
up)
• grinding crack due to wrong coo- • cool uniformly
ling • have the clearance in the spindle
• excessive clearance in the spindle bearing arrangement re-adjusted
bearing arrangement (vibrations)

Cut thread is wrong • tool is clamped incorrectly or has • adjust tool to the centre, grind
been started ginding the wrong angle correctly. Use tool 60° for
way metric threads, tool 55° for inch-
based threads.
• wrong pitch • adjust right pitch
• wrong diameter • in a previous step, turn the work-
piece to the correct diameter
© 2009
GB

22 / 09 / 2009 Malfunction Lathe D 330 x 1000 ; Version 1.2 Page 133

OPTIMUM Appendix

MASCHINEN - GERMANY

11 Appendix
11.1 Copyright
© 2009
This documentation is copyright. All derived right are also reserved, especially those of transla-
tion, re-printing, use of figures, broadcast, reproduction by photo-mechanical or similar means
and recording in data processing systems, neither partial nor total.
The company reserves the right to make technical alterations without prior notice.

11.2 Terminology/Glossary
Term Explanation

headstock housing for the feed gear and the synchro-

nous belt pulleys

leadscrew nut split nut which engages in the leadscrew

lathe chuck clamping tool for holding the workpiece

drill chuck device for holding the bit

lathe saddle slide on the slideway of the machine bed

which feeds parallel to the tool axis

cross slide slide on the lathe saddle which moves

transversely to the tool axis

top slide swivelling slide on the cross slide

taper manrel taper of the bit, the drill chuck or the cen-
tre

tool cutting too, bit, etc.

workpiece piece to be turned or machined

tailstock movable turning aid

rest follow or steady support for turning long

workpieces

lathe dog device or clamping aid for driving pieces

to be turned between centres

threading gauge auxiliary device for thread-cutting

© 2009 GB

Page 134 Appendix Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Appendix
OPTIMUM
MASCHINEN - GERMANY

11.3 Liability claims for defects / warranty

Beside the legal liability claims for defects of the customer towards the seller the manufacturer
of the product, OPTIMUM GmbH, Robert-Pfleger-Straße 26, D-96103 Hallstadt, does not grant
any further warranties unless they are listed below or had been promised in the frame of a single
contractual agreement.
• The processing of the liability claims or of the warranty is performed as chosen by OPTIMUM
GmbH either directly or through one of its dealers. Any defective products or components of
such products will either be repaired or replaced by components which are free from defects.
The property of replaced products or components passes on to OPTIMUM GmbH.
• The automatically generated original proof of purchase which shows the date of purchase,
the type of machine and the serial number, if applicable, is the precondition in order to assert
liability or warranty claims. If the original proof of purchase is not presented, we are not able
to perform any services.
• Defects resulting of the following circumstances are excluded from liability and warranty
claims:
• Using the product beyond the technical options and proper use, in particular due to over-
straining of the machine
• Any defects arising by one's own fault due to faulty operations or if the operating manual is
disregarded
• Inattentive or incorrect handling and use of improper equipment
• Non-authorized modifications and repairs
• Insufficient installation and safeguarding of the machine
• Disregarding the installation requirements and conditions of use
• Atmospheric discharges, overvoltage and lightning strokes as well as chemical influences
• The following items are as well not subject to the liability or warranty claims:
• Wearing parts and components which are subject to a standard wear as intended such as
e.g. V-belts, ball bearings, illuminants, filters, sealings, etc.
• Non reproducible software errors
• Any services which OPTIMUM GmbH or one of its agents performs in order to fulfill in the
frame of an additional guarantee are neither an acceptance of the defects nor an accept-
ance of its obligation to compensate. Such services do neither delay nor interrupt the war-
ranty period.
• Place of jurisdiction among traders is Bamberg.
• If one of the above mentioned agreements is totally or partially inefficient and/or null, it is
considered as agreed what is closest to the will of the warrantor and which remains in the
framework of the limits of liability and warranty which are predefined by this contract.

11.4 Note regarding disposal / options to reuse:

Please dispose of your device environmentally friendly by disposing of scrap in a professional
way.
Please neither throw away the packaging nor the used machine later on, but dispose of them
according to the guidelines established by your city council/municipality or by the corresponding
waste management enterprise.
© 2009
GB

22 / 09 / 2009 Appendix Lathe D 330 x 1000 ; Version 1.2 Page 135

OPTIMUM Appendix

MASCHINEN - GERMANY

11.4.1 Decommissioning
CAUTION
Used devices need to be decommissioned in a professional way in order to avoid later
misuses and endangerment of the environment or persons
• Pull off the mains plug.
• Disconnect the connection cable.
• Remove all environmentally hazardous operating fluids from the used device.
• If applicable remove batteries and accumulators.
• Disassemble the machine if required into easy-to-handle and reusable
assemblies and component parts.
• Supply the machine components and operating fluids to the provided disposal routes.

11.4.2 Disposal of the packaging of new devices

All used packaging materials and packaging aids of the machine are recyclable and generally
need to be supplied to the material reuse.
The packaging wood can be supplied to the disposal or the reuse.
Any packaging components made of cardboard box can be chopped up and supplied to the
waste paper collection.
The films are made of polyethylene (PE) and the cushion parts are made of polystyrene (PS).
These materials can be reused after reconditioning if they are forwarded to a collection station
or to the appropriate waste management enterprise.
Only forward the packaging materials correctly sorted to allow a direct reuse.

11.4.3 Disposing of the old device

INFORMATION
Please make sure in your own interest and in the interest of the environment that all component
parts of the machine will be disposed of in the provided and admitted ways.
Please note that the electrical devices include lots of reusable materials as well as environmen-
tally hazardous components. Account for separate and professional disposal of the component
parts. In case of doubt, please contact your municipal waste management. If appropriate, call on
the help of a specialist waste disposal company for the treatment of the material.

11.4.4 Disposal of electrical and electronic components

Please make sure that electrical components are disposed of in a professional way according to
the legal requirements.
The device includes electric and electronic components and must not be disposed of with the
rubbish. According to the European directive 2002/96/EG regarding electrical and electronic
used devices and the execution of national rights used electrical tools and electrical machines
need to be collected separately and be supplied to an environmentally compatible reuse.
Being the machine operator you should obtain information regarding the authorized collection or
disposal system which applies for your company.
Please make sure that the batteries and/or accumulators are disposed of in a professional way
according to the legal regulations. Please only throw discharged batteries in the collection boxes
in shops or at municipal waste management companies.
© 2009 GB

Page 136 Appendix Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

Appendix
OPTIMUM
MASCHINEN - GERMANY

11.4.5 Disposal of lubricants and coolants

ATTENTION
Please imperatively make sure to dispose of the used coolant and lubricants in an
environmentally compatible way. Observe the disposal notes of your municipal waste
management companies.

INFORMATION
Used coolant emulsions and oils should not be mixed up since it is only possible to reuse used
oils which had not been mixed up without pre-treatment.
The disposal notes for the used lubricants are made available by the manufacturer of the lubri-
cants. If necessary, request the product-specific data sheets.

11.5 Disposal
Disposal of used electric and electronic machines
(Applicable in the countries of the European Union and other European countries with a sepa-
rate collecting system for those devices).
The sign on the product or on its packing indicates that the product must not be handles as com-
mon household waist, but that is needs to be delivered to a central collection point for recycling.
Your contribution to the correct disposal of this product will protect the environment and the
health of your fellow men. The environment and the health are endangered by incorrect dis-
posal. Recycling of material will help to reduce the consumption of raw materials. Your District
Office, the municipal waste collection station or the shop where you have bought the product will
inform you about the recycling of this product.

11.6 RoHS , 2002/95/CE

The sign on the product or on its packing indicates that this product complies with the European
guideline 2002/95/EC .
© 2009
GB

22 / 09 / 2009 Appendix Lathe D 330 x 1000 ; Version 1.2 Page 137

OPTIMUM Appendix

MASCHINEN - GERMANY

11.7 Product follow-up

We are required to perform a follow-up service for our produts which extend beyond shipment.
We would be grateful if you could send us the following information:
• modified settings
• experiences with the lathe which could be important for other users
• recurring failures

Optimum Maschinen Germany GmbH

Dr.-Robert-Pfleger-Str. 26
D-96103 Hallstadt
Telefax +49 (0) 951 - 96 822 - 22
E-Mail: [email protected]
© 2009 GB

Page 138 Appendix Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009

OPTIMUM
MASCHINEN - GERMANY

11.8 EC - Declaration of conformity

The manufacturer / Optimum Maschinen Germany
retailer: Dr.-Robert-Pfleger-Str. 26
D-96103 Hallstadt
hereby declares that the following product,
Type of machine: Lathe
Name of machine: D 330 x 1000
Relevant EU-directives:
Machinery Directive 98/37/EC, Annex II A
EMV - Directive 89/336/EEC
Low voltage Directive 2006/95/EC
meets the provisions of the aforementioned directive, including any amendments valid at the
time of this statement.
In order to ensure confirmity, the following harmonized standards in particular have been
applied:

EN 12840: 2001 Safety of machine tools - Manuylly controlled turning machines with
or without automatic control
EN 62079 Setting up instructions - structure, content and presentation
(IEC 62079:2001)

Thomas Collrep Kilian Stürmer

(Manager) (Manager)

Hallstadt, 28.11.2008
© 2009
GB

22 / 09 / 2009 Version 1.2 D 330 x 1000 Lathe Page 139

OPTIMUM Index

MASCHINEN - GERMANY

12 Index
A Thread types 59
adjusting threads 43 Transport 23
appendix 134 tread-cutting 49
assembly Turning 52
rests 40 Turning cones 68
Turning off 66
B
British threads 62
C
Cones 68
coolant 49
Cutter 55
Cutting material 71
Cutting off 66
Cutting speed 72
Cutting speed table 51, 73
Cutting speeds 51
D
declaration of conformity 139
E
EG - declaration of conformity 139
External threads, Internal threads 58
G
Grinding of cutting edge geometries 73
I
indicating element 35
Installation 26
M
malfunction 132
Metric thread 61
O
obligations
operator 10
user 10
operation 33
Outside machining 57
P
Prohibition, warning and mandatory labels 13
protection
-equipment 15
Protective cover
Headstock 13
Q
qualification of personnel 9
R
Recessing 66
S
safety
during maintenance 16
during operation 15
safety check 14
safety devices 11
switching the lathe on 38
T
tailstock 46
© 2009 GB

technical data 18

Seite 141 Index Lathe D 330 x 1000 ; Version 1.2 22 / 09 / 2009