Holzmann ED 400FD User manual

HOLZMANN-MASCHINEN GmbH
Marktplatz 4 · 4170 Haslach · Austria Gewerbepark 8 · 4707 Schlüsslberg · Austria
Telefon [phone] Telefon [phone]
Telefax +43.(0)7289.71562-4 Telefax +43.(0)7248.61116-6
Email [email protected] www.holzmann-maschinen.at
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Revision 3/ 06.05.2011
HOLZMANN ED 400FD
DEUTSCH ENGLISH

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Dear Customer!
This manual contains Information and im-
portant instructions for the installation and
correct use of the metal lathe ED 400FD
This manual is part of the machine and
may not be stored separately from the
machine. Save it for later reference and
if you let other persons use the machine,
add this instruction to the ma-chine.
Please read and obey the security instruc-
tions!
Before rst use read this manual
carefully. It eases the correct use
of the machine and prevents misunder-
standing and damages of machine and the
user’s health.
Due to constant advancements in product
design and construction pictures and con-
tent may di-verse slightly. However, if you
discover any errors, inform us please with
the product feedback form.
Technical specications are subject to
changes!
Copyright © 2011
This document is protected by internati-
onal copyright law. Any unauthorized du-
plication, translation or use of pictures,
illustrations or text of this manual will be
pursued by law – court of jurisdiction is
A-4020 Linz, Austria!
Sehr geehrter Kunde!
Diese Bedienungsanleitung enthält Infor-
mationen und wichtige Hinweise zur Inbe-
triebnahme und Handhabung der Metall-
drehbank ED 400FD
Die Bedienungsanleitung ist Bestandteil
der Maschine und darf nicht entfernt wer-
den. Bewahren Sie sie für spätere Zwecke
auf und legen Sie diese Anleitung der Ma-
schine bei, wenn sie an Dritte weitergege-
ben wird!
Bitte beachten Sie die Sicherheits-
hinweise!
Lesen Sie vor Inbetriebnahme diese Anlei-
tung aufmerksam durch. Der sachgemäße
Umgang wird Ihnen dadurch erleichtert,
Missverständnissen und etwaigen Schä-
den wird vorgebeugt. Halten Sie sich an
die Warn- und Sicherheitshinweise. Miss-
achtung kann zu ernsten Verletzungen
führen.
Durch die ständige Weiterentwicklung un-
serer Produkte können Abbildungen und
Inhalte gering-fügig abweichen. Sollten
Sie jedoch Fehler feststellen, informieren
Sie uns bitte über E-Mail oder Fax mit Pro-
duktinformationsformular am Ende dieser
Anleitung.
Technische Änderungen und Irrtümer vor-
behalten!
Urheberrecht © 2011
Diese Dokumentation ist urheberrechtlich
geschützt. Die dadurch verfassungsmäßi-
gen Rechte bleiben vorbehalten! Insbe-
sondere der Nachdruck, die Übersetzung
und die Entnahme von Fotos und Abbil-
dungen werden gerichtlich verfolgt – Ge-
richtsstand ist A-4020 Linz, Austria!
ENGLISH DEUTSCH

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1. GENERAL SAFETY RULES
Read and understand the owner’s manual and labels afxed to
the machine. Learn its application and limitations as well as the
specic potential hazards peculiar to it.
Keep working area and the ground clean and free of oil and other
materials!
Assure that the working area is sufciently lighted!
Don’t use the machine outside!
The use of the machine is forbidden if you are tired, not concen-
trated as well if you are under the inuence of medicaments, al-
cohol and other drugs. Reduce distraction sources in the working
area.
BEWARE: Routine leads to insufcient attention.
The machine shall be used only by trained persons wiht an age
of at least 18 years.
Non authorized personnel, especially children, shall be kept away
from the machine! Make your workshop childproof.
When working with the machine, don’t wear loose clothing, long
hair openly or loose jewellery like necklaces etc. Loose objects
might be catched by rotating parts and cause serious injuries.
Use proper safety clothing and devices when operating the ma-
chine (safety glasses, ear protectors)!
Assure yourself that your feeding current complies with the re-
quirements of the motor - check the typeplate.
Electric checks and the electric installation of the machine may
only be performed by a qualied electrician.
DO NOT touch leading machine parts.
Prior to any Cleaning, Check, maintenance or tool change shut
the machine off and disconnect it from the power supply in order
to prevent unintended start up of the machine.
READ THE MANUAL
AVOID DANGEROUS CONDITIONS
OPERATOR
CLOTHING
SAFETY EQUIPMENT
ELECTRIC CONNECTION
ENGLISH

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MAINTAIN SAFETY GUARDS, COMPONENTS AND SIGNS
NEVER FORCE YOUR MACHINE
DO NOT OVERREACH
SECURE SMALL WORKPIECES
MAINTAIN TOOLS WITH CARE
It will do a better job if used at its designed output rate.
Forcing your machine shortens it`s lifespan, may cause machine
defects and poses a security risk.
Keep proper footing and balance at all times.
When processing small workpieces, x them with a suitable de-
vice like a vice, downholder, to avoid accidents.
Do not x or feed small workpieces by hand.
Keep your hands away from dangerous area, allways guide the
workpiece or tool securely.
Assure yourself to keep your working tools always sharp and in
best working condition.
Defect or blunt tools pose a security risk.
Assure yourself, that all safety guards and safety devices of your
machine are working in best condition. Damaged Safety guards
have to be repaired before using the machine again.
Check the function of the machines Safety components like
Emergency OFF Buttons and Disconnectors in regular intervals.
Defect Safety components have to be replaced immediately.
Check the condition of the Safety signs and operation rule plates
on your machine. Replace missing or non-readable ones.
Before leaving the machine, shut it off and wait until the motor
and all rotating parts stop.
Form a habit to check that there are no tools, keys, wrenches ...
on the machine/tool before you start the machine.
Remove all accessories and tools from the machine before you
switch it on.
NEVER LEAVE MACHINE RUNNING UNATTENDED
REMOVE UNUSED TOOLS, KEYS, WRENCES
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ENGLISH
This metal turning lathe shall be used expicitly for turning and
drilling of metal and plastic materials suitable for chip remo-
val.
The processing of other materials is not allowed!
never process magnesium - Burn Hazard!
Besides the information of this manual and the specic work sa-
fety rules valid in your country you should be familiar (through
proper education & experience) with the specic operation, sa-
fety and processing rules that have to be obeyed when working
with a metal lathe.
Do not wear gloves when working with the machine.
It might be catched in rotating parts and cause severe inju-
ries.
Comply to the rules of max. workpiece diameter, length etc ...
Always check the fastening tool to be mounted properly so that
it cannot become loose.
Check the workpiece for being fastened correctly.
Use the lathe chucks within the frame they are designed.
Do not attempt to fasten workpieces with diameters that do not
match with the chuck. Do not overfasten the chuck.
Process only short workpieces without tailstock.
Additionally, if the workpiece length is more than 3 times the
workpiece diameter, the workpiece has to be secured with the
tailstock as well by all means.
Avoid the combination of short fastening diameters with big
machining diamterers.
Avoid short fastening lengths
Always be informed about the technical limitations of your tools.
Especially - never use a tool at turning speeds that lie above the
max. alowed turning speed of the tool.
Perform tapping, threading in general and the machining of non
centrally fastenend workpieces only at slow turning speeds.
2. SPECIFIC RULES
CORRECT USE
OBEY THE SPECIFIC WORK RULES FOR METAL LATHES

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The workplace must have:
sufcient lighting conditions to prevent
shadows or eye strain.
a clean, level underground that is vibrati-
on resistent! We strongly recommend to
install the the metal lathe onto a solid,
vibration-resistent workbench.
enough place around the machine for safe
handling and feeding of the material.
A proper, compatible electric supply cir-
cuit.
Humidity: max. 90% for max. 25°C
max. 70% for max. 40°C
height above sea level: max. 1000m
Do not use the machine outdoors.
Do not use the machine in workplaces
with explosion and re hazard.
The work with a metal lathe always con-
tains a certain risk that can never be eli-
minated entirely. This is a non comple-
te shortlist indicating some of the most
dangerous remaining residual risks:
Risk of personal injury due to coming into
contact with the rotating workpiece or
rotating chuck.
Risk of personal injury through chips -
wear safety goggles.
Risk of electrocution when touching lea-
ding machine components.
Risk of personal injury by touching sharp
workpiece edges.
You can minimize these residual risks by
following all security, maintenance and
operation rules.
WORKPLACE REQUIREMENTS INAPPROPRIATE MACHINE USAGE
RESIDUAL RISKS
Any use that does not comply with the
security rules, maintenance guidelines or
operation rules described in this manual.
Any use that does not comply to max.
workpiece dimensions, max. turning
speed or other technical limitations.
The use of the machine by not sufcient-
ly trained persons in general.
HOLZMANN Maschinen cannot be made
liable for any damages to machine and
person being a direct or indirect conse-
quence of inproper use of the machine.
ENGLISH

3. MACHINE SETUP
Remove the wooden crate around the la-
the.
Check the contents of the shipping con-
tainer:
ED 400FD metal lathe
Test Flow Chart
Toolbox
Contents of the Toolbox:
See Figure 2
1 Dead center MT3
1 Dead center MT2
3 External Jaws
1 Oil gun
1 Cross screwdriver
1 Flat screwdriver
1 Key for 3-Jaw chuck
5 Hex Socket wrenches
3 Double End Head Wrenches
1 Change Gears
Unbolt the lathe from the shipping crate
bottom.
Choose a location for the lathe that:
fulls all requirements from the security
section.
With adequate lifting equipment, slowly
raise the lathe off the shipping crate bot-
tom.
DO NOT LIFT the machine by a spindle.
Make sure that the lathe is balanced be-
fore lifting it.
Lifting has to be performed by respectivel
trained persons.
ATTENTION
!
Read and understand the security and
Machine setup sections of this manual
before attempting to set-up the machi-
ne.
Failure to do so might result in machine
damage or even serious injuries!
CHECK DELIVERY CONTENT
SETTING TO WORKPLACE
To avoid twisting the bed, the lathe`s lo-
cation must be absolutely at and level.
Bolt the lathe to the stand (if used). If
using a bench, through bolt for best per-
formance. Check Figure 1 for the boring
hole distances.
Clean all rust protected surfaces using
a mild commercial solvent, kerosene or
diesel fuel. Do not use paint thinner ga-
solone or lacquer thinner. These will da-
mage painted surfaces. Cover all cleaned
surfaces with a light lm of 20W machine
oil.
Remove the end gear cover. Clean all
components of the end gear assembly
and coat all gears with a heavy, non-slin-
ging grease.
Lubricate the machine at all lubrication
points and ll the oil reservoirs to ope-
rating level before placing the lathe into
service!
Instructions for lubrication can be found
in the maintenance section of this manu-
al.
LUBRICATE ALL SLIDEWAYS LIGHTLY
BEFORE EVERY USE. LUBRICATE THE
CHANGE GEARS AND THE LEADSCREW
SLIGHTLY WITH A LITHIUM-BASED GRE-
ASE.
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4. MACHINE DESCRIPTION
The ED 400FD is a High Quality metal
turning lathe, especially designed for the
sophisticated private user but as well
for professional workshops requiring the
machine for processing small to middle
workpieces.
The lathe bed is made of high-grade iron
with low vibration and rigidity. It integra-
tes the headstock and drive unit, for at-
taching the carriage and leadscrew. The
two precision-ground V-sideways, re-
enforced by heat hardening and grinding,
are the accurate guide for the carriage
and tailstock. The main motor is mounted
to the rear of the left side of the bed.
The headstock is cast from high grade,
low vibration cast iron. It is bolted to the
machine bed with four screws. The head-
stock houses the main spindle with two
precision taper roller bearings and the
drive unit.
The main spindle transmits the torque
during the turning process. It also holds
the workpieces and clamping devices
(e.g. 3-jaw chucks)
The carriage is made from high quality
cast iron. The slide parts are smoothly
ground. They t the V on the bed without
play. The lower slide parts can be easily
and simply adjusted. The cross slide is
mounted on the carriage and moves on
a dove tailed slide. Play in the cross slide
may be adjusted with the gibs.
Move the cross slide with the hand-
wheel.
A four way tool post is tted on the top
slide and allows four tools to be clamped.
Loosen the center clamp handle to rotate
any of the four tools into position.
The apron is mounted on the bed. It
houses the half nut with an engaging le-
ver for activating the automatic feed.
LATHE BED - FIG. 3
The half nut gibs can be adjusted from
the outside.
A rack, mounted on the bed, and a pinion
operated by handwheel on the carriage
allow for quick travel of the apron.
The leadscrew A is mounted on the front
of the machine bed. It is connected to
the gearbox at the left for automatic feed
and is supported by bearing on both ends.
The hex nut B on the right end is desig-
ned to take up play on the leadscrew.
The tailstock slides on a V way and can
be clamped at any location. The tailstock
has a heavy-duty spindle with a morse
taper MT2 socket and a graduated scale.
The spindle can be clamped at any loca-
tion with a clamping lever. The spindle is
moved with a handwheel at the end of
the tailstock.
Fit the securing screw C at the end of the
lathe on order to prevent the tailstock
from falling off the lathe bed.
See gure 10, number D. The machine
can be switched on and off with the ON/
OFF button. Depress to stop all machine
functions. To restart, lift the cover and
press the green ON button.
See gure 10, number E. After the ma-
chine is switched on, turn the spindle di-
rection switch E to the position „F“ for
counter clockwise rotation or to position
„R“ for clockwise spindle rotation. „0“ is
the OFF position and the spindle remains
idle.
See gure 10, number F. Turn the cont-
rol knob clockwiese to increase and anti
clockwise to reduce the spindle speed.
The speed range depends from the drive
belt position.
CARRIAGE - FIG. 5
HEADSTOCK - FIG. 4
APRON - FIG. 6
LEADSCREW - FIG. 8
TAILSTOCK - FIG. 9
EMERGENCY BUTTON ON/OFF
SPINDLE DIRECTION SWITCH
VARIABLE SPEED CONTROL KNOB
ENGLISH

CARRIAGE LOCK - Fig. 11
Turn the hex socket cap screw A clockwi-
se and tighten it to lock. Turn it counter-
clockwise to loosen and unlock.
CAUTION: The carriage lock screw must
be unlocked before engaging into auto-
matic feeds! Otherwise machine damage
might occur.
See Figure 12, number B.
Rotate the handwheel clockwise to move
the apron assembly towards the tailstock
(right).
Rotate the handwheel counter-clockwise
to move the apron assembly towards the
headstock (left).
See Figure 12, number C.
Clockwise rotation moves the cross slide
towards the rear of the machine.
See Figure 12, number D.
Move the lever down to engage. Move
the lever up to disengage.
See Figure 12, number E.
Rotate the lever to move the compound
rest.
See Figure 12, number F.
Rotate counter-clockwise to loosen and
clockwise to tighten. Rotate the tool post
when the lever is unlocked.
See Figure 13, number G.
Turn hex nut clockwise to lock and coun-
ter-clockwise to unlock.
See Figure 13, number H.
Rotate the lever clockwise to lock the
spindle and counter-clockwise to unlock.
LONGITUDINAL TRAVERSE HANDWHEEL
CROSS TRAVERSE LEVER
HALF NUT ENGAGE LEVER
COMPOUND REST TRAVERSE LEVER
TOOL POST CLAMPING LEVER
TAILSTOCK CLAMPING SCREW
TAILSTOCK QUILL CLAMPING LEVER
See Figure 13, number I
Rotate clockwise to advance the quill.
Rotate counter-clockwise to retract the
quill.
See Figure 13, number J
Three set screws loacted on the tailstock
base are used to off-set the tailstock for
cutting tapers. Loosen lock screw on tail-
stock end. Loosen one side set screw whi-
le tightening the other until the amount
of off-set is indicated on scale. Tighten
lock screw.
TAILSTOCK QUILL TRAVERSE HANDWHEEL
TAILSTOCK OFF-SET ADJUSTMENT
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5. TECHNICAL DATA
Swing Over Bed 210mm
Swing OVer Cross Slide 110mm
Distance Between Centers 400mm
Width of Bed 100mm
Hole Through Spindle 21mm
Taper in Spindle Nose MT3
Number of Spindle Speeds Variable
Range of Spindle Speeds 50-2500RPM
Number of Metrich Threads 10
Range of Metrich Thread 0-5~3.0mm
Number of Imperial Threads 8
Range of Imperial Thread 8~44 T.P.I.
Range of Longitudinal Feed 0.1~0.2mm
Tool Post Type 4-Way
Maximum Compound Slide Travel 85mm
Maximum Cross Slide Travel 80mm
Maximum Carriage Travel 290mm
Tailstock Spindle Travel 55mm
Taper in Tailstock Spindle MT2
Main Motor 600W
Voltage/Frequ. 230V/1Ph/50Hz
Length 930mm
Width 390mm
Height 370mm
Weight 65kg
Technical Changes in the frame of product development preser-
ved.
CAPACITIES
HEADSTOCK
FEEDING AND THREADING
COMPOUND AND CARRIAGE
TAILSTOCK
GENERAL
ENGLISH

6. OPERATION
The head spring holding xture is cylind-
rical. Loosen three set screws A and nuts
(See Figure 14 - only two are visible on
the picture).
Position the new chuck and x it using
the same set screws and nuts.
1. See Figure 16
Unscrew the two fastening screws
B and remove the protective cover.
2. See Figure 17
Adjust the V-belt C to the
corresponding position.
There are two V-belt positons:
Pos. A (outer pulleys) for lower speed
range.
Pos. B (inner pulleys) for higher speed
range.
3. Tighten the tension pulley and
fasten the nut again.
REPLACEMENT OF CHUCK
CHANGE SPEED
TOOL SET-UP
Clamping the turning tool into the tool-
holder.
The tool must be clamped rmly. When
turning, the tool has a tendency to bend
under the cutting force generated during
the chip formation. for best results, tool
overhang should be kept to a minimum
of 3/8“ (~ 9mm) or less.
The cutting angle is correct when the cut-
ting edge is in line with the center axis
of the workpiece. The correct height of
the tool can be achieved by comparing
the tool point with the point of the center
mounted in the tailstock. If necessary,
use steel spacer shims under the tool to
get the required height (see Figure 15).
See. Figure 19
Apron travel, cross travel and top slide
handwheel can be operated for longitudi-
nal or cross feeding.
See. Figure 18
Use the table A on the lathe for selecting
the feed speed or the thread pitch. Ad-
just the change gear if the required feed
or thread pitch cannot be obtained with
the installed gear set.
1. Disconnect the machine from the
power source.
2. Unscrew the two fastening screws
and remove the protective cover.
MANUAL TURNING
LONGITUDINAL TURNING WITH AUTO-FEED
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See Figure 20:
3. Loosen the locking screw B on the
quadrant.
4. Swing the quadrant C to the right.
5. Unscrew the nut D from the
leadscrew or the nuts E from the
quadrant bolts in order to remove
the change gears from the front.
6. Install the gear couples according
to the thread and feed table
(Fig. 21 and 22) and screw the
gearwheels onto the quadrant
again.
7. Swing the quadrant to the left until
the fearwheels have engaged
again.
8. Readjust fear backlash by inserting
a normal sheet of paper as an
adjusting or distance aid between
the gearwheels.
9. Immobilize the quadrant with the
locking screw.
10. Install the protective cover of the
headstock and reconnect the
machine to the power supply.
In the straight 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 saddle or the top slide, or by acti-
vating the automatic feed. The crossfeed
for the depth of cut is achieved using the
cross slide.
In the facing operation, the tool feeds
perpendicular to the axis of the workpie-
ce. The feed is made manually with the
cross slide handwheel. The crossfeed for
cut depth is made with the top slide or
lathe saddle.
STRAIGHT TURNING - Fig. 39
FACING AND RECESSES - FIG. 41
For turning between centers, it is neces-
sary to remove the chuck from the spind-
le. Fit the MT3 center into the spindle nose
and the MT2 center into the tailstock.
Mount the workpiece tted with the dri-
ver dog between the centers. The driver
is driven by a catch or a face plate.
Note: Always use a small amount of gre-
ase on the tailstock center to prevent
center tip form overheating.
Work to a side angle of 5 can be turned
by off-setting the tailstock. The angle de-
pends on the length of the workpiece.
See Figure 7:
To off-set the tailstock, loosen locking
screw A. Unscrew the set screw B on the
right end of the tailstock. Loosen the front
adjusting screw C and take up the same
amount by tightening the rear adjsuting
screw D until the desired taper has been
reached. The desired cross-adjustment
can be read off the scale E. First retighten
the set screw B and then the two (front
and rear) adjusting screw to lock the tail-
stock in position . Retighten the locking
screw A of the tailstock. The workpiece
must be held between to centers and dri-
ven by a face plate and driver dog.
After taper turning, the tailstock should
be returned to it`s original position ac-
cording to the zwero position on the scale
E of the tailstock.
Set the machine up to the desired thread
pitch (according to the threading chart).
Start the machine and engage the half
nut. When the tool reaches the part, it
will cut the initial threading pass. When
the tool reaches the end of the cut, stop
the machine by turning the motor off and
at the same time back the tool out of the
part so that it clears the thread. Do not
disengage the half nut lever. Reverse the
motor direction to allow the cutting tool
to traverse back to the starting point.
Repeat these steps until you have obtai-
ned the desired results.
TURNING BETWEEN CENTERS - FIG. 40
TAPER TURNING USING TAILSTOCK
OFF-SET
THREAD CUTTING - FIG. 42
ENGLISH
CHANGE GEARS REPLACEMENT

ENGLISH

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ENGLISH
7. LATHE ACCESSORIES
See Figure 26
Using this universal chuck you can clamp
round, triangular, square, hexagonal, oc-
tagonal and dodekonal cornered work-
pieces.#
For the original 3-jaw chuck being moun-
ted on the lathe, the factory has mounted
the chuck in the best way to guarantee
the holding accuracy with two „0“ mark,
see A, Fig. 26, showed on the chuck and
chuck ange.
There are two types of jaws: Internal
and external jaws. Please note that the
number of jaws t with the number insi-
de the chuck`s groove. Do not mix them
together. When you are going to mount
them, please mount them in ascending
order 1-2-3, when you are going to take
them out, be sure to tkae them out in de-
scending order 3-2-1, one by one. after
you nished this procedure, rotate the
jaws to the smallest diameter and check
that the three jaws are well tted.
See Figure 27:
This special chuck has four indepenent-
ly adjustable chuck jaws. These permit
the holding of asymmetrical pieces and
enable the accurate set-up of clyindrical
pieces.
Use the drill chuck (B, Figure 28) to hold
centering drills and twist drills in the tail-
stock.
THREE JAW UNIVERSAL CHUCK
NOTE
!
New lathes have very tight tting jaws.
This is necessary to ensure accurate
clamping and long service life. With re-
peated opening and closing, the jaw ad-
justs automatically and their operation-
becomes progressively smoother.
FOUR JAW INDEPENDENT LATHE CHUCK
DRILL CHUCK (OPTIONAL)
See Figure 28, C
An arbor is necessary for mounting the
drill chuck in the tailstock. It has a No. 2
morse taper.
See Figure 29:
the live center D is mounted in ball bea-
rings. Its use is highly recommended for
turning at speeds in excess of 600rpm.
See Figure 30:
The steady rest serves as a support for
shafts on the free tailstock end. For many
operations the tailstock can not be used
as it obstructs the turning tool or dril-
ling tool, and therefore, must be remo-
ved from the machine. The steady rest,
which functions as an end support, en-
sures chatter-free operation. The steady
rest is mounted on the bedways and is
secured from below with a locking pla-
te. The sliding ngers require continuous
lubrication at the contact points to pre-
vent premature wear.
Setting the Steady rest
• Loosen the three hex nuts A
• Loosen the knurled screw B and open
the sliding ngers C until the steady
rest can be moved with its nger
around the workpiece. Secure the
steady rest in position.
• Tighten the knurled screws so that n-
gers are snug but not tight against the
workpiece. Tighten the three nuts A.
Lubricate the sliding points with ma-
chine oil.
• When, after prolonged operation, the
jaw shows wear, the tips of the ngers
may be led or remilled.
The follow rest is mounted on the sadd-
le and follows the movement of the tool.
Only two sliding ngers are required. The
place of the third nger is taken by the
turning tool. The follow rest is used for
MORSE TAPER ARBOR (OPTIONAL)
LIVE CENTER (OPTIONAL)
STEADY REST
FOLLOW REST