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Industrial Resources, Inc. Manual LatheMachine Shop (IRI-MS01-EMD)
Revision 0 – September 2, 2004 Page 12
The lathe is equipped with an aftermarket Digital Readout (DRO) ( Figure 8 ) that displays the
movement of the cross slide (cross feed) and carriage (longitudinal feed). The readout for “X” is
the cross slide and “Z” is for the carriage movement. The DRO is very versatile in that in cantrack tool movement (material removed or tool position) as well as material remaining to be
removed either in a straight line or as a function of diametrical sizing.
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The dense, fine grain structure of Meehanite metal which assures casting solidity and consistent
physical properties relate the carbide stability of the molten metal, both before and after
processing to the casting section.
Figure 10 – Lathe Bed and Ways
The bed and ways support the remainder of the lathes parts and hold the machines machining
accuracy to tight tolerances over extended periods of time so long as the lathe has been properly
setup or installed on its foundation.
The “ways” of the lathe are an integral part of the lathe bed and are precision ground to exacting
tolerances to allow for the precision machining of a work piece in the longitudinal direction
(using the carriage feed). The ways also locate the tailstocks centerline in line with the
headstocks centerline throughout the tailstocks travel on the ways.
2.2 Headstock
The headstock ( Figure 11 ) houses the spindle along with its support bearings, spindle speed
gears as well as turning and threading feed gears. The lathes chuck (work piece mountingdevice) is attached to the spindle by way of six (6) cam lock pins. The headstock spindle is belt
driven from the drive motor and through the spindle speed gears ( Figure 12 ).
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The headstock is equipped with an oil flow sight glass as seen in Figure 11 and also an oil level
sight glass located just below the drive belt access door on the end of the headstock where the oil
level should be maintained at the center of the glass. When the machine (motor) is running thereshould be a steady stream of oil showing in the oil flow sight glass. The headstock is lubricated
with Dextron D.T.E. 26 hydraulic oil.
2.3 Speed Change Gears (Spindle RPM)
The different spindle speeds are selected by turning the spindle speed selector to the desired
position and moving the speed selector lever to the High, Medium or Low range as needed for
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For turning, facing and boring operations the C-D Lever is always in the “D” position and the “C”
position is used only for cutting Metric or Module threads. The A-B Lever selects heavy or light
feeds when performing turning, facing or boring operations while it selects coarse or fine threadsduring threading operations with “A” equaling heavy or coarse and “B” equaling light or fine.
The feed rate for “longitudinal” (carriage) feeds is different from those in the cross feed (cross slide)
direction. The finest longitudinal feed is 0.002 (two-thousandths of an inch) per spindle revolution
while the finest cross feed is 0.0005 (½ thousandth of an inch) per spindle revolution. The different
feed rates are a result of the final gearing in the carriage apron and are necessary because the surface
speed of the work piece decreases as the tool is fed towards the center of the material.
The feed selections for the carriage (longitudinal) feed are shown in the chart above and reflect
the different positions of the feed levers and feed dial. You will notice that the P-L-KJH lever is
always in the “KJH” or “H” position when turning, facing or boring a work piece. This is
reflective of the fact that the “K and “J” positions are for threading only with the designation “K”having only one (1) thread pitch (threads per inch) selection of 19-threads per inch when
Industrial Resources, Inc. Manual LatheMachine Shop (IRI-MS01-EMD)
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Turning and boring (carriage movement) is accomplished by pushing the Feed Selection Push-
Pull Knob “in” and pushing “down” on the Feed Engagement Lever. Facing (cross slide
movement) is accomplished by pulling the Feed Selection Push-Pull Knob “out” and pushing“down” on the Feed Engagement Lever ( Figure 17 ). Pulling “up” on the Feed Engagement
Lever in either instance will disengage the feed.
Feed Selection Push-Pull Knob
Thread Chasing Dial
Threading Engagement Lever
Feed Engagement Lever
Figure 17 – Feed Selection Arrangement
Threading (carriage movement only) is accomplished by pushing “down” on the Threading
Engagement Lever at the appropriate time to engage the lead screw nut. The Thread Chasing
Dial indicates the proper time to engage the threading nut with the lead screw ( Figure 17 ).
The thread chasing dial is equipped with a worm gear that engages with the lead screw, which
causes the dial to rotate when the lead screw is turning.
Industrial Resources, Inc. Manual LatheMachine Shop (IRI-MS01-EMD)
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Oil Level Sight Glass
One Shot Oil Pump
Figure 19 – Oil Pump and Oil Sight Glass
Oiling of the ways is accomplished by pulling out on the oil pump knob and releasing it to allow
the internal return springs to pump oil to the ways with oiling being done once per day. The oil
level in the apron must be maintained in the center of the sight glass to allow for the splash oilingof the apron gears and must be replenished (filled) as oiling of the ways takes oil from the apron
reservoir each time the ways are oiled. Dextron D.T.E.-27 is used as the lubricant.
Also located on the carriage/apron are the manual carriage travel and cross slide handwheels as
well as the automatic feed and threading engagement levers as described in the previous Section
2.4 .
The apron is equipped with two (2) push-pull knobs that control selection of the feed axis
[longitudinal (carriage) or cross (cross slide)] as well as the direction of feed (forward or reverse
on the carriage and in or out on the cross slide). Forward on the carriage would be towards the
headstock with reverse being away from the headstock ( Figure 20 ).
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The compound rest is so named because it is upon the compound that the cutting tool holder and
thus the cutting tool rest. The compound can be used to machine and angle or taper in a work
piece or set a single point threading tool up at the right feed angle (29 degrees) for threading awork piece by advancing the compound and thus the cutting tool after each tool pass until the
required thread depth and/or thread classification fit are achieved.
A tool holder or other peripheral device is mounted to the compound by way of a “T” slot in the
compound located at the uppermost and forward section of the compound as can be seen in
Figure 23 on the preceding page.
Any machining done using the sliding motion of the compound only is strictly “manual” as there
are no provisions for automatic feeding of the compound on this lathe.
2.8 Thread Chasing Dial
The thread chasing dial ( Figure 24 ) allows the operator to choose the starting point of a threading
operation. The dial consists of numbered graduated marks that indicate the correct time to engage
the threading gear based on the desired thread pitch (threads per inch or threads per millimeter).
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The thread chasing dial works off the lead screw and is used as a tracking device. The dial tells
the operator when to engage the half nut lever so the tool follows the same thread groove every
time. The lathes machining feed selection (turning, boring and facing) must be in “neutral”when cutting threads with only the lead screw turning and NOT the feed drive bars.
The proper engagement point or line on the dial depends on the number of threads per inch or per
millimeter that is required. Generally speaking, once the correct starting point is selected
(numbered line or otherwise) the safest bet is to use the same starting point (line) for each
successive pass to prevent starting in the middle of a thread high point and destroying the
threads.
The thread chasing dial will turn when the lead screw is turning or when the carriage is moved
forward or reverse when turning or boring operations are being performed on a work piece. In
other words, the thread dial worm gear is in mesh or contact with the lead screw at all times and
is only useful (used) when actually threading a work piece with the turning, boring and facing
feed in neutral.
2.9 Tailstock and Steady RestThe lathes tailstock ( Figure 25 ) has multi purposes. With the use of a live or dead center it can
be used to support the work piece by way of a centering hole that has been drilled in the end of
the work piece.
The tailstock can also be used to drill a hole in the end of a work piece that is gripped by the
chuck. Depending on the length of the work piece it may need to be supported by a steady rest
(Figure 26 ) in order to facilitate the drilling of a centering hole, which would then allow the
work piece to be supported by a live, or dead center. The steady rest could then be removed to
enable turning of the outside diameter of a work piece.
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At any point along the travel of either the carriage or the cross slide, the DRO can be zeroed out
(0.000) to allow for a “next step” measurement or datum point for then moving the carriage or cross
slide in either direction and allowing the operator to come back to the zero point at any time byreversing travel direction of the selected axis or device (carriage or cross slide).
Detailed instructions for setting the different parameters of each axis are covered in the operations
Safety/Environmental:• Wear hard hats, safety glasses, safety toe shoe, and ear plugs as required.• Discuss environmental hazards associated with performing maintenance of the equipment.• Discuss any safety precaution that must be observed while performing the procedure.
Note: Always observe all plant safety rules in accordance with Safety and Health Procedures and all
Industrial Resources, Inc. Manual LatheMachine Shop IRI-MS01-JPM
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Part C: Preparation for Maintenance
This is to be performed under direction of the Shop Supervisor.
Demonstrate the following preparation for use of the Manual Lathe including:1. Prior to performing any work with the Manual Lathe, clear the work area of clutter and
ensure adequate lighting exists to perform the desired work.2. Ensure the spindle start lever on the carriage is in the neutral position prior to turning the
power on to the lathe.3. Do NOT wear loose clothing when operating the lathe.4. Ensure there is an adequate amount of cutting fluid in the reservoir.5. Never leave the chuck wrench in the chuck when not actually in use.6. Ensure the proper use of safety equipment such as safety glasses when operating the lathe.
7.
Ensure that all guards are in place prior to starting the machine.8. Oil the lathes ways at the start of each day’s first use of the lathe.9. Isolate electrical power prior to performing any maintenance work on the lathe.
This is to be performed under direction of the Shop Supervisor.
Demonstrate the following operational steps for the safe and efficient operation of the ManualLathe.1. Check that the machines chip pan and ways are clear of any debris or previously used
material.2. Make sure that the proper lubrication oil to all moving parts have been completed and that
the reservoirs are filled (headstock and carriage apron).3. Make sure that the spindle control lever at the apron is in the neutral position.4. Turn the power on to the lathe by turning the ON/OFF switch to the “ON” position and
observing that the “ON” indicating light is illuminated.
5.
If needed, turn the coolant pump on by turning the ON/OFF switch to the “ON” positionand observe that the “ON” indicating light is illuminated.6. To start the spindle turning forward (counter clockwise) pull up on the spindle control
lever located on the right side of the carriage apron.(Continued)
Industrial Resources, Inc. Manual LatheMachine Shop IRI-MS01-JPM
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Part D: Operating Procedure (Continued)
7.
To stop the spindle, move the spindle control lever to the “neutral” position by pushing itdown from the “forward” position and step on the foot brake bar/pedal.8. To start the spindle in reverse (clockwise), pull the spindle lever out (to the right away
from the carriage) and push it down.9. For an emergency “STOP” step on the foot brake bar/pedal or depress the Emergency
“STOP” button on the power panel.10. Select the desire spindle speed by choosing Low, Medium or High range with the
associated lever, using the spindle “Jog” button if necessary.11. Select the desired RPM by turning the speed selection dial (use the spindle “Jog” button if
necessary).
Feed and Thread Selection1. Using the feed and/or thread charts, select the desired feed rate or thread pitch.2. Make sure the carriage “spindle control lever” is in the “neutral” position and the spindle is
NOT turning.3. Move the gear change levers to the desired configuration for the selected feed/thread pitch.4. Do NOT force the change levers when engaging into the selected position(s). (Use the
gear turning knob located under the headstock back cover to help mesh the gears.)
Turning Boring and Facing Operations
1. Place the work piece in the chuck and indicate in a necessary.
2.
Start the spindle turning by pulling up on the spindle control lever.3. Using the manual carriage and cross slide handwheels, locate the cutting tool at the work piece for the first machining pass.
4. For longitudinal machining (turning or boring) push in on the feed axis push-pull knob andfor cross slide machining (facing) pull out on the knob.
5. For “forward” longitudinal (towards the headstock) or cross slide feed (away from theoperator), push the forward/reverse push-pull knob in, and for reverse feed, pull the knobout.
6. Ensure the cutting tool elevation is aligned with the centerline of the work piece.7. Using the manual feed handwheels (carriage and cross slide) traverse the work piece the
desired length or distance of required machining with the spindle stopped.8. Set the feed stops at the end(s) of travel if so desired.9. Make adjustments in the tooling setup as necessary to complete the machining operation
using the automatic feed(s).10. Move the carriage and/or cross slide as necessary to bring the tool to its start position.11. Start the spindle turning in the desired direction by pulling up or pushing down on the
Industrial Resources, Inc. Manual LatheMachine Shop IRI-MS01-JPM
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Part D: Operating Procedure (Continued)
12.
Engage the carriage or cross slide feed by pushing down on the feed engagement leverlocated on the front of the carriage apron.13. If feed stops are used, ensure that they engage the feed stop lever at the appropriate time or
manually stop the feed at the desired point.14. Continue the machining operation until such time as the desired dimension and/or profile
of the work piece is accomplished.15. Remove the work piece from the chuck by loosening the chuck jaws.16. Using a paint brush or similar item, clear the lathe ways, cross slide and carriage of all
machining debris (chips) and clean out the chip pan as needed.17. Turn the lathe off by turning the ON/OFF switch to the “OFF” position and turn the
This is to be performed under direction of the Shop Supervisor.
Demonstrate the steps on the Manual Lathe required to perform the following preventive
maintenance tasks.
Cleaning and Lubrication1. Clean the chip pan as needed.2. Clear machining chips from the lathes horizontal surfaces after each use.3. Check the level of the cutting fluid reservoir and add as needed.4. Lubricate the bed ways daily (as used) with light machine oil.5. Check the oil level in the headstock periodically and add D.T.E. 26 oil as needed.6. Check the apron oil level daily and add D.T.E. 27 oil as needed.7. Every 4 to 6 weeks, drain and refill the coolant reservoir with fresh coolant/cutting fluid.
Industrial Resources, Inc. Manual LatheMachine Shop IRI-MS01-JPM
6. (IRI-MS01-Q) The spindle start/stop lever is located on __________.A. the left side of the carriage apronB. the right side of the carriage apronC. the front of the headstockD. the front of the carriage apron
7. (IRI-MS01-Q) The headstock uses D.T.E. ______ oil for lubrication of the internal gears and bearings.A. 26B. 27C. 28D. 29
8. (IRI-MS01-Q) The lathes ways are constructed of ___________.A. hardened and ground tool steelB. gray cast ironC. MeehaniteD. cold rolled boiler plate
9. (IRI-MS01-Q) Threading on the lathe is accomplished by engaging the thread feed lever at the
appropriate time based on the position of___________.A. the tool bitB. thread dialC. the work pieceD. tailstock
10. (IRI-MS01-Q) Under normal operating conditions, pulling up on the spindle start/stop lever willcause the spindle to ________________________.A. stop turningB. turn in a reverse direction
C. turn in a clockwise directionD. turn is a counter clockwise direction