Fervi 0657 User manual

USE AND
MAINTENANCE MANUAL
Bench lathe
Art. 0657
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
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FOREWORD
Read this manual before any operation
ORIGINAL INSTRUCTIONS
Before starting any operation it is compulsory to read this instruction manual. The guarantee
that the machine will function and perform properly is strictly dependent upon the application
of all the instructions contained in this manual.
Operator Qualification
The operators assigned to using this machine must be supplied with all of the necessary
information and instruction and should be provided with adequate training regarding
safety in pertaining to:
a) The conditions of use of the equipment;
b) Foreseeable abnormal situations, pursuant to Article 73 of Legislative Decree
81/08.
We guarantee the Machine's conformity to the specifications and technical instructions
described in the Manual on the date of issuance and listed herein; On the other hand,
the machine may also be subject to important technical changes in the future, without
the manual being updated.
Therefore, see FERVI for information about modifications that could be implemented.
REV. 3
February 2014
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CONTENTS
1INTRODUCTION ........................................................................................5
1.1 Preface..........................................................................................................................6
2SAFETY WARNINGS ..................................................................................7
2.1 General safety rules for machine tools..........................................................................7
2.2 Special safety rules for lathes .......................................................................................9
2.3 Safety rules for electrical machine equipment ..............................................................9
2.4 Technical support........................................................................................................10
2.5 Other provisions .........................................................................................................10
3TECHNICAL SPECIFICATIONS ................................................................. 11
4DESCRIPTION OF THE MACHINE ............................................................. 13
4.1 Intended use and field of application ..........................................................................13
4.2 Description of the main parts......................................................................................14
4.2.1 Supporting table...................................................................................................... 14
4.2.2 Head and spindle ..................................................................................................... 15
4.2.3 Spindle speed change............................................................................................... 15
4.2.4 Automatic feed setting.............................................................................................. 16
4.2.5 Tool holder slide and carriage.................................................................................... 16
4.2.6 Tailstock................................................................................................................. 17
4.3 Identification plate .....................................................................................................17
4.4 Pictograms..................................................................................................................18
5SAFETY DEVICES ON THE MACHINE ........................................................ 20
5.1 Electrical safety devices..............................................................................................20
5.2 "Mechanical" Safety Devices .......................................................................................21
5.2.1 Protective screens.................................................................................................... 21
5.3 Personal Protective Equipment (PPE) .........................................................................23
6FORBIDDEN USES AND HAZARDS ........................................................... 24
7LIFTING, TRANSPORTATION AND STORAGE ........................................... 26
7.1 Lifting .........................................................................................................................26
7.2 Transportation ............................................................................................................27
7.3 Warehouse storage .....................................................................................................27
8ASSEMBLY AND COMMISSIONING .......................................................... 28
8.1 Identification of the installation site ...........................................................................28
8.2 Support base...............................................................................................................28
8.3 Levelling the machine .................................................................................................28
8.3.1 Preliminary phase .................................................................................................... 28
8.3.2 Transverse levelling of the table ................................................................................ 29
8.3.3 Levelling the lathe guide rails .................................................................................... 29
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8.4 Operations before starting the machine......................................................................29
8.4.1 Cleaning the machine............................................................................................... 29
8.4.2 Lubrication and greasing........................................................................................... 29
8.4.3 Connection to the power supply network..................................................................... 29
8.4.4 Open circuit test ...................................................................................................... 30
9DESCRIPTION OF CONTROLS .................................................................. 31
9.1 Control buttons ...........................................................................................................31
9.1.1 Control panel buttons and pilot lamps......................................................................... 31
9.2 HAND WHEELS AND CONTROL LEVERS ........................................................................32
9.2.1 Hand wheels for the carriage and tool holder slides ...................................................... 32
9.2.2 Automatic feed activation lever.................................................................................. 33
9.2.3 Tailstock lever and handwheel................................................................................... 34
10 OPERATION.......................................................................................... 35
10.1 Traditional turning ...................................................................................................36
10.2 Milling ......................................................................................................................38
10.3 How to set the spindle speed ...................................................................................40
10.4 How to set up the automatic feed of the carriage ....................................................41
11 MAINTENANCE ..................................................................................... 46
11.1 Lubrication...............................................................................................................46
11.2 Periodic checks ........................................................................................................49
11.3 Adjusting the Machine .............................................................................................49
11.3.1 Adjusting the tension of the belts............................................................................... 49
11.3.2 Tailstock alignment .................................................................................................. 49
11.3.3 Adjusting the play of the slides.................................................................................. 50
12 DISPOSAL OF PARTS AND MATERIALS .................................................51
13 ELECTRICAL SYSTEM ............................................................................ 52
14 TROUBLESHOOTING ............................................................................. 53
15 ACCESSORIES AND SPARE PARTS ........................................................ 54
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1INTRODUCTION
This manual is delivered with the machine, and it must be regarded as an inseparable part of
it.
The manufacturer holds all ownership to material and intellectual property of this manual;
any disclosure or copying, even partial, of this publication without prior written consent is
forbidden.
The purpose of this manual is to provide the knowledge necessary for the use and
maintenance of the Bench lathe Art. 0657 and create a sense of responsibility and
knowledge of the possibilities and limits of the device entrusted to the operator.
As the machine is entrusted to experienced and skilled operators, the following machine must
be perfectly known by the operator if it is to be used safely and effectively.
Operators must be properly trained and prepared, so make sure that this manual is read and
consulted by the staff responsible for commissioning, operation and maintenance of the
Bench lathe. This is to make all operations the safest and most effective possible for those
who carry out these tasks.
Therefore, it is imperative to strictly comply with the requirements in this manual, a
necessary condition for safe and satisfactory operation of the machine.
Prior to installation and use of the Bench lathe, authorised personnel must:
carefully read this technical document;
know which protections and safety devices are available on the machine, their location
and how they work.
The buyer is responsible for ensuring that users are properly trained, that they are aware of
all the information and instructions in this document and that they are aware of the potential
risks of operating the Bench lathe.
The manufacturer waives any and all responsibility for damage to people and/or
things caused by non-observance of the instructions in this manual.
The Bench lathe has been designed and built with mechanical guards and safety devices
designed to protect the operator/user from possible injury. It is strictly forbidden to modify or
remove guards, safety devices and caution labels. If this must be done (for example, for
cleaning or repair), make sure that no one can use the machine.
Modifications to the machine carried out by the user must be considered their sole
responsibility, therefore the manufacturer waives any and all responsibility for any
damage caused to persons and/or property resulting from maintenance performed
by unqualified personnel and in a manner unlike the operating procedures shown
below.
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GRAPHIC REPRESENTATION OF SAFETY,OPERATIONAL AND RISK WARNINGS
The following boxes are designed to attract the attention of the reader / user for the proper
and safe use of the machine:
Pay attention
This highlights behavioural rules to prevent damage to the machine and/or the occurrence of
dangerous situations.
Residual Risks
This highlights the presence of dangers that cause residual risks to which the operator must
pay attention in order to avoid injury or damage to property.
1.1 Preface
For safe and easy operation of the Bench lathe, this manual must be read carefully in order to
acquire the necessary knowledge. In other words, durability and performance are strictly
dependent on how it is used.
Even if already familiar with the Bench lathe, it is necessary to follow the instructions
contained herein, in addition to the general precautions to be observed while working.
Acquire full knowledge of the machine.
Read this manual carefully to understand: operation, safety devices and all necessary
precautions. All this is to allow safe use of the machine.
Wear appropriate clothing for the job.
The operator must wear appropriate clothing, so as to prevent the occurrence of
unpleasant accidents.
Maintain the machine with care.
Using the machine
The machine must only be used by qualified personnel trained to use the machine by
authorized personnel.
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2SAFETY WARNINGS
2.1 General safety rules for machine tools
Risks associated with the use of the machine
Do NOT underestimate the risks related to the use of the machine and stay focused on the
work you are carrying out.
Risks associated with the use of the machine
Despite the implementation of all safety devices for safe use of the machine, it is necessary to
take note of all the accident prevention requirements highlighted in various parts of this
manual.
Risks associated with the use of the machine
Every person who is responsible for the use and maintenance of the machine should first have
read the instruction manual, particularly the chapter dealing with safety.
It is recommended that the plant safety manager get written confirmation of the above.
Risks associated with the use of the machine
During all work phases with the machine, you should proceed with great caution in
order to avoid damage to persons, to property or to the machine itself.
Please only use the machine for its envisaged uses.
Do not tamper with the safety devices provided by the manufacturer.
Risks associated with the use of the machine
Before starting any work on the machine, the operator must wear the appropriate personal
protective equipment (PPE) such as gloves and eye protection.
1. Always check the efficiency and integrity of the machine.
2. Before connecting the machine to the mains make sure that the switch is in the rest
position.
3. Do not start the machine in an enclosed or poorly ventilated area, or in the presence of
a flammable and/or explosive atmosphere. Do not use the machine in damp and/or wet
locations, or those exposed to rain or humidity.
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4. Avoid starting accidentally.
5. Before starting the machine, get used to ensuring that no remaining adjustment or
maintenance wrenches have remained inserted.
6. Keep the workplace tidy and free from hindrances; disorder causes accidents.
7. Make sure that the work environment is forbidden to children, non-employees and
animals.
8. Do not perform tasks on the machine other than those for which it was designed. Only
use the machine in the manner in which it was intended, as described in this instruction
manual.
9. Work without disturbances.
10.Work areas must be well lit.
11.Always wear eye protection and protective gloves while working. If dust is produced,
use the appropriate masks.
12.Wear appropriate clothing. Loose clothing, dangling jewellery, long hair, etc.., can get
caught in the moving parts, causing irreparable injury.
13.Replace worn and/or damaged parts, check that the guards and protection devices work
properly before operating. If necessary, have the machine checked by the service
support personnel. Use only original spare parts.
14.Cut the mains voltage supply to the machine when:
the machine is not being operated;
is left unattended;
you are performing maintenance or adjustment because the machine does not
work properly;
the power cable is damaged;
you are replacing its tool;
in case the machine is being moved to another location;
you are cleaning the machine.
15.Do not use the machine in areas with a risk of fire and/or explosion.
16.It is recommended that users of this publication, for maintenance and repair, have a
basic knowledge of mechanical principles and of repair technique procedures.
17.The person responsible for company safety is to make sure that the staff
responsible for using the machine have read and understood this manual in its
entirety.
18.The company safety manager is responsible for monitoring the company's risk
status according to Legislative Decree no. 81/08.
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2.2 Special safety rules for lathes
1. Firmly secure the workpiece before starting the lathe, using the jaws installed on the
spindle.
2. Always use the tool in an appropriate manner. Perform only the work for which the tool
is made. Do not use the tool for inadequate work.
3. Only use suitable resistance tools in relation to the work that is to be done. This is to
avoid risky and unnecessary overloading for the operator, which may be harmful for
the life of the tools themselves.
4. Do not pick up moving tools or other moving parts. To stop the moving parts on the
machine, always only use the stop command device.
5. Before performing any measurement of the workpiece mounted on the spindle, turn the
motor off, unplug it and wait for the spindle to stop.
6. Do not remove the shavings with your hands, even at a standstill. To do this, use tongs
or a palette knife.
7. When the work tools need to be replaced or the speed needs to be changed, stop the
motor, unplug it and wait for the spindle to stop.
8. Do not leave the machine until the equipment and other moveable parts are completely
stopped.
9. After the work is completed, clean the tool and check its efficiency.
2.3 Safety rules for electrical machine equipment
Risks associated with the use of the machine
1. Do not modify the electrical system in any way. Any attempt in this regard may
jeopardize the operation of electrical devices, thus causing malfunction or accident.
2. Work carried out in the electrical system of the machine must, therefore, be carried out
only by qualified and authorized personnel.
3. If one hears unusual noises, or feels something strange, immediately stop the machine.
Then carry out an inspection and, if necessary, perform any repairs as required.
1. Ensure supply voltage complies with the label and technical specifications (230 V / 50
Hz).
2. It is necessary to use a device for the automatic interruption of the power supply in
case of failure, which is to be coordinated with the machine's electrical system. For
more detailed information, contact a trusted electrician.
3. The mains power outlet should be bipolar grounded (10/16 A, 250 V), extension cables
must have sections that are the same or greater than the sections of the power cable
of the machine.
4. The power supply cable (and its possible extension cable) should never come in contact
with hot objects, sharp edges, wet or oiled surfaces.
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5. The power cord should be checked regularly and before each use to check for signs of
damage or wear. If these are not in good condition, replace the cable.
6. Do not use the power cord to lift the machine or to remove the plug from the socket.
2.4 Technical support
For any problems or concerns, please contact, without hesitation the Customer Service
Department of your dealer, who has competent and specialized staff, specific equipment and
spare parts.
2.5 Other provisions
IT IS FORBIDDEN TO TAMPER WITH SAFETY DEVICES
The first thing to do when starting work is to check for the presence and integrity of the
protections and the operation of the safety devices.
If any defect is encountered do not use the machine!
Even more so, it is strictly forbidden to modify or remove guards, safety devices,
labels and indication signs.
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3TECHNICAL SPECIFICATIONS
Description (unit of measurement)
0657
Centre height (mm)
125
Distance between the points (mm)
550
Spindle hole diameter (mm)
20
Maximum swing over the bed (mm)
250
Spindle diameter (3 + 3 self centring) (mm)
125
Conical spindle attachment
CM / MT 3
No. of spindle speeds
6
Spindle speed (r/min)
125 –2000
Range of metric threads (mm)
0.4 –3.0
Range of inch threads (TPI)
10 –44
Tailstock attachment
CM / MT 2
Dimensions (W x D x H) (mm)
1325 x 550 x 1230
Package dimensions (W x D x H) (mm)
1230 x 730 x 610 h
Weight (kg)
160
Voltage / power supply frequency (V / Hz)
230/50.
Motor power (W)
550
Emitted sound pressure level (dB (A))
69.6 2.94
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Accessories supplied
Milling device
Bench lathe stand
3 external jaws
Spindle key
Gear 30T (30 teeth)
Gear 40T (40 teeth)
Gear 42T (42 teeth)
Gear 50T (50 teeth)
Gear 52T (52 teeth)
Gear 60T (60 teeth)
Gear 66T (66 teeth)
Gear 70T (70 teeth)
Gear 75T (75 teeth)
Gear 80T (80 teeth)
Square head key
Allen key, 3 mm
Allen key, 4 mm
Allen key, 5 mm
Allen key, 6 mm
Key 5.5 / 7 mm
Key 8 / 10 mm
Key 12 / 14 mm
Key 17 / 19 mm
Centring device MT 2
Centring device MT 3
Gear 40T fixed to the shaft
Key 45 / 52 for round nuts
Fuse
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4DESCRIPTION OF THE MACHINE
The Bench lathe Art. 0657 is a machine tool, with a horizontal axis, for the machining of
metallic materials by means of cold chip removal.
The machine is completely manually operated, as it can only execute movements under the
direct control of the operator.
4.1 Intended use and field of application
The machine is designed and constructed primarily for the following work processes:
1. Traditional turning: cylindrical turning, facing, drilling and boring, threading, etc.
In this case, the cutting motion is given by the motion of the workpiece, rotating on its
own axis, and the feed motion of the tool.
2. Milling.
In this case, the cutting motion is given by the motion of the tool (milling cutter),
rotating on its own axis, and the feed motion of the workpiece mounted on the
appropriate fastening device supplied.
Intended use and materials
The machine has been designed and manufactured for the uses specified.
Any use and lack of respect for the technical parameters established by the manufacturer may
be dangerous to operators; therefore, the manufacturer cannot assume any liability for
resulting damages.
The lathe is equipped with a support base and must be installed and used on flat surfaces,
with ergonomic features and adequate resistance. Furthermore, sufficient space should be left
around the machine to ensure proper maintenance and cleaning of all parts of the machine
can be carried out.
The lathe can operate in enclosed working environments (production departments,
warehouses, etc.), i.e. those that are protected from the weather and where there is no
danger of fire or explosion.
The operating temperature is within the range of +5 / +50°C.
The environment must also be sufficiently illuminated so as to ensure operation in maximum
safety (at least 50 lux is recommended).
The Lathe consists of two basic units:
the spindle;
tool holder slide assembly (carriage)
The first is constituted by the spindle and by the components that transmit motion from the
motor to the spindle.
The second is constituted by the tool holder carriage and the parts that transmit motion to
the tool holder carriage during the automatic feed motion.
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4.2 Description of the main parts
The Bench Lathe Art. 0657 consists of the following main parts:
Figure 1 - Main parts of the lathe
1
Supporting table
6
Control panel
2
Tailstock
7
Pulley and gear compartment
3
Carriage and tool holding
slides
8
Electrical panel
4
Head and spindle
9
Tool holder handwheels
5
Interlocked spindle guard
10
Feed activation lever
4.2.1 Supporting table
The supporting table is made of cast iron; the casting has been stabilised to avoid torsion
and/or deformities due to the internal stresses in the material. At the top there are prismatic
guides that ensure the movement and alignment of the motor head with the carriage and
mobile head (tailstock). The rails have been hardened and overhauled. They have been
prepared with reinforcing ribbing that increases rigidity.
1
2
3
4
5
6
7
8
9
10
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4.2.2 Head and spindle
The different spindle speeds are obtained by means of a
gearbox with transmission belts (see also section 4.2.3 of this
manual).
The spindle is installed on the head shaft, and is supported by
precision bearings.
It is self-centring, with three clamps (jaws) which permit the
work piece to be locked safely and stably.
Figure 2 –Spindle.
For the opening / closing of the jaws it is necessary to insert a special key in the housing
(square cross-section), on the outer contour of the spindle.
The danger zone, in the vicinity of the spindle, is protected by a moveable interlocking guard,
which consists of a polycarbonate screen plate with micro-safety switch.
4.2.3 Spindle speed change
The adjustment of the spindle rotation speed is obtained by positioning the drive belt, housed
in the gear compartment, as indicated on the following plate.
Figure 3–Plate and spindle speed pulleys.
Adjusting the Speed
Despite the presence of the micro-safety switch on the casing to access the pulleys, it is
forbidden to change the speed of rotation before turning off the machine and unplugging the
power cord.
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On the control panel, there is a selector to set the spindle's
direction of rotation:
if rotated to the right, the spindle rotates clockwise;
if rotated to the left, the spindle rotates anti-clockwise;
Figure 4 –Selector.
4.2.4 Automatic feed setting
The setting of the automatic feed of the tool holder carriage
for threading operations, is achieved by correctly positioning
the gears for transferring motion from the electric motor to
the lead screw.
The lathe is provided with gears that can guarantee the
considerable availability of feeds and threads (metric and
inch).
Figure 5 –Feed gears.
4.2.5 Tool holder slide and carriage
The carriage, which slides along the rails of the table, is used
to fix the tool, and to drive the movement and feeding
actions.
The various parts are made of cast iron with ground and
hardened rails for greater stability.
The cart is equipped with a system that ensures the
lubrication of moving parts.
The hand-wheels to move the machine and the levers are
easy to reach and easy to use.
Figure 6 –Tool holder
carriage.
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4.2.6 Tailstock
The tailstock is constituted by a cast iron body that ensures
rigidity and stability in any conditions of use. The tailstock
body is equipped with a locking system on the lathe guides.
An adjustment screw, allows axial alignment of the tailstock to
be achieved.
Inside a steel sleeve has been fitted. Movement is applied via
a handle equipped with a micrometer.
Figure 7–Tailstock.
4.3 Identification plate
The following Identification Plate is attached to the Machine:
Figure 8 –Identification plate.
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4.4 Pictograms
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Pictograms Key
PLATE IN ITALIAN
PLATE IN ENGLISH
LEGGERE LE ISTRUZIONI PRIMA DI UTILIZZARE LA
MACCHINA
NON AVVICINARE LE MANI ALL’UTENSILE IN MOVIMENTO
NON AFFERRARE L’UTENSILE CON LE MANI PER
ARRESTARLO
NON REGOLARE LA MACCHINA MENTRE E’ IN FUNZIONE
INDOSSARE SEMPRE IDONEE PROTEZIONI, QUALI
OCCHIALI E MASCHERINE QUALORA VENGA PRODOTTA
POLVERE
SCOLLEGARE LA MACCHINA DALL’ALIMENTAZIONE
ELETTRICA IN CASO DI RIPARAZIONI O REGOLAZIONI
NON INDOSSARE INDUMENTI SVOLAZZANTI, GIOIELLI,
CATENINE E BRACCIALI CHE POSSONO AGGANCIARSI
ALLA MACCHINA E PROVOCARE DANNI IRREPARABILI
SCOLLEGARE LA MACCHINA DALL’ALIMENTAZIONE
ELETTRICA PRIMA DI ESEGUIRE MANUTENZIONE,
REGOLAZIONI E RIPARAZIONI
PLEASE READ THE INSTRUCTIONS BEFORE USING THE
MACHINE
KEEP HANDS AWAY FROM THE MOVING TOOL
DO NOT GRAB THE PIECE BY HAND TO STOP IT
DO NOT ADJUST THE MACHINE WHILE IT IS IN OPERATION
ALWAYS WEAR SUITABLE PROTECTIVE EQUIPMENT SUCH
AS GOGGLES AND MASKS IF POWDER IS PRODUCED
DISCONNECT THE MACHINE FROM THE POWER SUPPLY IN
THE EVENT OF REPAIRS OR ADJUSTMENTS BEING MADE
DO NOT WEAR CHAINS OR BRACELETS THAT CAN GET
CAUGHT IN THE MACHINE AND CAUSE IRREVERSIBLE
DAMAGE
DISCONNECT THE MACHINE FROM THE POWER SUPPLY
BEFORE PERFORMING MAINTENANCE, REPAIRS AND
ADJUSTMENTS
ATTENZIONE
È VIETATO ESEGUIRE LAVORI SU
APPARECCHIATURE ELETTRICHE SOTTO
TENSIONE
EVENTUALI DEROGHE DEVONO ESSERE
AUTORIZZATE DAL CAPO RESPONSABILE
IN CONDIZIONI DI PARTICOLARE PERICOLO DEVE
ESSERE PRESENTE UN’ALTRA PERSONA OLTRE A CHI
ESEGUE IL LAVORO
INIZIARE I LAVORI SOLO AD AVVENUTA
ATTAZIONE DELLE MISURE DI SICUREZZA
In ottemperanza al Dgs.81/08 relativo alla prevenzioni
infortuni
ATTENTION
IT IS FORBIDDEN TO PERFORM WORK ON LIVE
ELECTRICAL EQUIPMENT
ANY EXCEPTIONS MUST BE APPROVED BY THE
MANAGER IN CHARGE
IN CONDITIONS OF PARTICULAR DANGER THERE
MUST BE ANOTHER PERSON PRESENT IN ADDITION
TO THE PERSON PERFORMING THE WORK
ONLY BEGIN WORK AFTER IMPLEMENTATION OF
THE SAFETY MEASURES
In accordance with the Legislative Decree 81/08 relating to
accident prevention
ATTENZIONE!
TOGLIERE LA
CORRENTE PRIMA
DI APRIRE IL
CARTER
ATTENTION!
CUT THE POWER
BEFORE OPENING
THE CASING
NON
RIMUOVERE
I DISPOSITIVI DI
SICUREZZA
È severamente
vietata la
rimozione e la
omissione dolosa
D.lgs. 81/08
DO NOT
REMOVE
THE SAFETY DEVICES
Malicious
omission or
removal is strictly
forbidden
Legislative
Decree 81/08
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MACHINES AND
ACCESSORIES
Page 20 of 69
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5SAFETY DEVICES ON THE MACHINE
5.1 Electrical safety devices
Figure 9 - Emergency button.
The machine is equipped with an emergency stop button, consisting of an emergency button
located below the on and off switches. In an emergency, if pressure is applied to the
emergency mushroom button, the dangerous functions stop.
The electrical panel is constructed in such a way that the electrical parts are not directly
accessible, in contact with dust, oil, coolant and other contaminants
The Lathe's power supply connection must be equipped with a grounding conductor
according to regulations.
Electric shock
Improper connection of the Lathe and/or the grounding conductor can result in the risk of
electric shock.
Check with a qualified electrician if you don't understand the grounding instructions
or if you have any doubts about grounding the machine.
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