MachineryHouse AL-356 User manual

INSTRUCTION MANUAL
AL-356
Centre Lathe (240V)
356 x 1000mm Turning Capacity - 51mm Bore
L564D
Page 1
Instructions Manual for AL-356 (L564D)
01/09/2017

CONTENTS
Preface…………………………………………………………………………………….………1
1. Safety rules for lathes……………………………………………………………….………1
2. Machine specification……………………………………………………………….………2
3. Constructional indication...………………………………………………………….………3
4. Unpacking and installation………………………………………………………….………4
4-1 Unpacking…………………………………………………………………….….……4
4-2 Cleaning……………………………………………………………………….………4
4-3 Installation…………………………………………………………………….…….…4
5. Lubarication…….……………………………………………………………………….……4
5-1 Headstock………………………………………………………………………..……4
5-2 Gearbox…………………………………………………………………………..……4
5-3 Apron….…………………………………………………………………………..……4
5-4 Change gears…………………………………………………………………….……4
5-5 Others parts……………………………………………………………………………4
6. Test running……………………………………………………………………………..……5
6-1 Operation Symbols……………………………………………………………………5
6-2 Spindle speed control…………………………………………………………………6
7. Thread and feed selection…………………………………………………………..………7
7-1 Thread and feed selection……………………………………………………………7
7-2 Feed and thread tables…………………………………………………….…………7
7-3 Threading dial indicator………………………………………………………………8
8. Electric circuit control………………………………………………………………………10
9. Chucks and chuck mounting………………………………………………………………10
10. Maintenance and servicing…………………………………………………………………11
10-1 Lathe alignmenat…………………………………………………………...………11
10-2 Saddle strip…………………………………………………………………………11
10-3 Cross slide…………………………………………………………………….……11
10-4 Compound rest……………………………………………………………….……12
10-5 Cross slide nut…………………………………………………………………..…12
10-6 Tailstock bed clamp…………………………………………………………….…12
11. Bed Assembly………………………………………………………………………………13
12. Headstock assembly………………………………………………………………………22
13. Gear box control……………………………………………………………………………29
14. Apron…………………………………………………………………………………………36
15. Cross slide & compound……………………………………………………………..……39
16. Tailstock Assembly…………………………………………………………………………47
17. Center rest & follow rest……………………………………………………………..……49
18. Coolant system & work light………………………………………………………………51
19. Electric assembly……………………………………………………………………..……53
20. Optional accessories………………………………………………………………………55
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Instructions Manual for AL-356 (L564D)
01/09/2017

PREFACE
For an efficient and appropriate way of utilization, also for extending the machine’s life, all the
operators are requested to carefully read the instruction of this Manual before start to operate.
Most of the operators think, according to their own experience, they can handle the machine
appropriately and hopeful to neglect what so important items in this booklet. Anyhow, we may say, as
per previous experiencing, that many of the breakdowns are resulted from ignoring the instructions of
the Manual. Although you have our one-year’s warranty for the damage caused by the defect of the
machine, either in material of functional, we will not take any responsibility for any damages arise out of
improper operation.
In the mean time, besides specification, operator should also thoroughly and deeply acknowledge
the character, function and maintenance of this machine before starting.
Generally, in addition to the description stated in coming chapter, you are requested to notice the
following points:
1. never install the machine in the place where the sun shines directly or where the radiation of
heat can reach for avoiding from affecting the accuracy of the machine.
2. use only the recommended lubrication oil.
3. clean the machine every time when finish working, or a cover will be a plus to prevent the dust.
4. try to get rid of chips or dusts especially in the grooves of the machine. Keep it as clean as
possible or it may be scratched.
5. whenever the grooves of the machine damaged by falling in extra articles, don’t ever try to
move Apron. It needs to be repaired to resume its work.
Hope this operation Manual can be of great assistance and provide you more convenience when
operating. The content of this Manual is the best solution derived from our long terms of manufacturing
and operating experience. We wish to service you always with an policy of upgrading quality and a
conviction in pursuit of perfection.
1. safety rules for lathes
safety is a combination of operator common sense and alertness at all times when lathe is being used.
Study these safety rules and general safety rules before operating and retain for future use.
1. wear eye protection.
2. Never attempt any operation or adjustment if procedure is not understood.
3. keep fingers away from revolving parts and cutting tools while in operation.
4. Never force cutting action.
5. Never perform an abnormal or little used operation without study and use of adequate blocks,
jigs stops, fixtures ECT.
6. Use of shop manual such as “machinery’s handbook” or similar is recommended for cutting
speeds feeds and operation detail.
7. Do not remove drive cover while machine is in operation. Make sure it is always closed.
8. Always remove chuck key, even when machine is not in operation.
9. Do not attempt to adjust or remove tools when in operation.
10. Always keep cutters sharp.
11. Never use in an explosive atmosphere or where a spark could ignite a fire.
12. Always use identical replacement parts when servicing.
WARNING: Do allow familiarity (gained from frequent use of your lathe) to become commonplace. A
careless fraction of a second can allow for sever injury.
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Instructions Manual for AL-356 (L564D)
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2. MACHINE SPECIFICATION
Bench lathe are especially suitable for machining, tool toms and repairing working shops to machine
shafts, spindle, sleeves, and disc work piece of middle or small types. They can also be used to cut
metric thread and imperial, and with compact construction and reasonable composition, they can cut
very well. They are easy and reliable to operate, convenient to repair high in efficiency, and low noise.
Technical specification
Swing over bed 330mm 356mm
Swing over support 198mm 224mm
Swing over gap 450mm 476mm
Center height 166mm 179mm
Distance between centers 750mm/1000mm 1000mm
Bed width 187mm 187mm
Bed height 305mm 305mm
Motor output 1.5kw 1.5kw
Spindle bore 51mm 51mm
Cam lock system D5 D5
Spindle taper MT No.6 MT No.6
Cross slide travel 160mm 160mm
Compound slide travel 68mm 68mm
Leadscrew diameter 22mm 22mm
Feed rod diameter 19mm 19mm
Cutting tool (Max. section) 20×20mm 20×20mm
Imperial thread 2¼-40TPI 2¼-40TPI
Metric thread 0.45-10mm 0.45-10mm
Longitudinal feed 0.078-1.044mm 0.078-1.044mm
Cross-feed 0.022-0.298mm 0.022-0.298mm
Tailstock quill diameter & taper 42mm / MT No.4 42mm / MT No.4
Weights (Approx.) 620kg 650kg
Voltage 240V-415V 240V-415V
Spindle speed 70-1900rpm 70-1900rpm
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Instructions Manual for AL-356 (L564D)
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3. constructional indication
1. Headstock
2. Speed Selector
3. Eclectic Control Box
4. Spindle With Three-Jaw Chuck
5. Tool Post
6. Work Lamp
7. Compound Rest
8. Compound Rest Handle
9. Coolant
10, Cross Slide
11. Quill Clamp Body
12. Quill Travers Handle
13. Tailstock
14. Tailstock Clamp Lever
15. Tailstock Set-Over Screw
16. Support Body
17. Bed
18. Foot- Brake
19. Spindle Control Lever
20. Longitudinal Traverse-Hand wheel
21. Longitudinal Traverse Hand Lever
22. Chip Tray
23. Apron
24. Feed Axis Selector
25. Thread Cutting Engagement Lever
26. Rack
27. Control Rod
28. Lead screw
29. Gear Box
30. Feed Box Selector
31. Feed Box Selector
32. Gear Box Cover
33. Feed Direction Selector
34. Speed Selector Lever
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Instructions Manual for AL-356 (L564D)
01/09/2017

4. UNPACKING AND INSTALLATION
4-1. Unpacking
Unload the machine with a tackle, using clamping plates and eyebolts. Keep the machine in balance by
moving the tailstock and the bed slide to the right. Avoid using sling chains as they could damage to
feed rod and leadscrew. Lift the lathe carefully and place it softly into the floor or workbench.
4-2 Cleaning
Before taking the machine into operation, using kerosene (paraffin) or white spirit to remove the
anti-corrosive coating or grease from all slideways and gear train. Don’t use lacquer thinner or other
caustic solvents. Oil all bright machine surfaces immediately after cleaning. Use heavy oil or grease on
the changes gears.
4-2. Installation
Place the lathe on a solid foundation. A
concrete floor is the best base for the machine.
(if necessary, use an under frame operational).
Make sure there is sufficient area around the
lathe for easy work and maintenance. Use a
precision level on the bedways to make further
adjustment for level condition, the tighten the
foundation bolts evenly and finally recheck for
level condition.
5. LUBRICATION
Before putting the lathe into operation, make the following lubrication check.
5-1. Headstock
The bearing of the headstock turns in an oil bath. Ensure that the oil level reaches three quarters of
the quarters of the oil gauge glass.
For exchanging the oil, remove the end cover and the change gears with swing frame. Drain off the
oil by removing the drain plug on the bottom of the headstock. To fill, take off the headstock cover.
Check the oil level regularly. The first oil change should be made after 3 month, then change it once
a year.
5-2. Gearbox
Remove the end cover to expose the filling plug. Through it the shell tellus 32 is filled to the oil level
in the oil gauge glass regularly. The first oil change should be made after three months, the change
it once a year.
5-3. Apron
The oil bath is filled with shell tellus 32 through the filling plug on the right side of the apron. Check
the oil level in the oil gauge glass on the front regular. The first oil change should be made after
three months, then change it once a year.
For exchanging the oil, drain away oil by taking off the drain plug on the bottom of the apron.
5-4. Change gears
Lubricate the change gears with thick machine oil or grease once a month.
5-5. Other parts
There are other lubricating points on the input shaft bracket of the gearbox, the handwheel on the
apron, the longitudinal and cross slide, the thread dial indicator, the tailstock and the bracket, use
the grease gun to put a few drops of oil from time to time. Lubricate the apron worm and worm gear,
half nut and leadscrew twice a month. Apply a light oil film to the bed way and all other bright parts
like the tailstock quill, feed rod ECT. Once a day.
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Instructions Manual for AL-356 (L564D)
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6. TEST RUNNING
6-1. Operation symbols
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Instructions Manual for AL-356 (L564D)
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6-2. Spindle speed control
A. Identification before operation
Ensure that lubrication has been carried out as described before.
When the main spindle is rotating, the gearbox and feed axis of the bedsides are put into operation.
The forward/reverse switch (21) should be on neutral. The feed axis selector (26) and feed / thread
selector handle (22) are in disengaged position. Under these circumstances, both the longitudinal
traverse handwheel and cross traverse handle (27) can be operated by hand.
B. Main spindle rotation
The main spindle rotation is selected by forward / reverse switch.
C. Main spindle speed
The speed of the main spindle is selecting by (high / low). Speed selector (3) and 4 steps speed
selector (2). For both high and low speed, there are 4 different positions. For correct speed, please
refer to the speed chart. When selector (3) is on “high”, we can get the four speeds, according to
the graph.
Never change the speed before the motor has stopped completely!
Adjustment the speed can be assisted by turn the main spindle by hand.
D. Running-in
Running in should be done at lowest possible spindle speed. Let the machine to run at lowest
speed for about twenty minutes, and then check for irregularities. If everything seems in order,
gradually increase the speed.
E. Operation
Use only high peripheral speed type chucks.
The maximum spindle speed for chuck plate of 254mm diameter should not be more than 1255rpm.
When thread cutting or auto feeding are not in use, the feed/thread selector should be in neutral
position, so as to ensure disengagement of the leadscrew and the feed rod. To avoid unnecessary
wear, the thread dial indicator should be out of mesh with the leadscrew.
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Instructions Manual for AL-356 (L564D)
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7. THREAD AND FEED SELECTION
7-1. Thread and feed selection
All threads and feeds are indicated on the tables fitted on the front and top of the gearbox. They are
selected with the feed selector handle on the gearbox.
A. Manual operation
The carriage is moved by the handle wheel (28), the cross slide by handle wheel (27) and the
compound rest by handle wheel (10). The slide can anchor by turning the lock bolts on the top and
the slide of the slide.
B. Feed and thread tables
Longitudinal and cross feed table. Metric and imperial thread table.
C. Automatic feed operation
Firstly, engage the 40T change gear at the transmission shaft and the 127T intermediate gear with
feed direction selector (38), next, set the feed/thread selector (34), To the left hand position and
position one lever (33) at any of the 1-8 hole, the other at any of A-E holes, thus the feed rod will
rotate. If selector (26) is pushed upward, a longitudinal feed can be obtained. If pushing downward,
across feed will be obtained.
D. Thread cutting operation
The direction of thread cutting is controlling by feed director (38). By operation feed selector handle
and feed / thread selector handle (34) according to thread pitch, the leadscrew rotate. Operate
downward the thread cutting engagement lever (22), it should be engaged with leadscrew, thus the
longitudinal travel of thread cutting feed.
7-2. Feed and thread tables
(A). Feed table:
Longitudinal and cross feed table for metric lathe
Longitudinal and cross feed table for imperial leadscrew
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Instructions Manual for AL-356 (L564D)
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(B) Thread tables
Thread table for metric leadscrew
Thread table for imperial leadscrew
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Instructions Manual for AL-356 (L564D)
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7-3. Thread cutting operation
In order to obtain the desired thread, all correct change gears must be installed in strict
accordance with the chart, failure to do so will give incorrect threads.
Rotate the leadscrew by operating the feed/thread selector to any position and be sure the feed
selector handle is engaged. Operate downward the thread cutting engagement lever (25), and it will be
engaged with the leadscrew to obtain the longitudinal travel of carriage, namely, the thread cutting feed.
Make sure the feed axis selector is disengaged (at neutral position) before operating the thread cutting
engagement lever (25) since there is an interlock mechanism between the auto feeding and thread
cutting engagement.
Direction of thread cutting can be chosen by turning the feed directing selector (33) at the
headstock. There are 31 Nos. of thread pitches each in Imperial, 26 Nos. of Metric pitches those which
can be obtained by turning the feed selector handles.
(A).Thread dial indicator
The thread dial indicator is installed on the right hand side of the apron the indicator is used for
thread cutting to engage with the leadscrew.
For minimum wear the thread dial indicator should be disengaged by swing the pinion out of mesh
with the leadscrew when not in use.
For these threads it is recommended that the thread dial indicator be used this allows the half nut
of leadscrew to be engaged at the end of each thread cutting pass, provided that they are re-engaged
in accordance with the indicator table mounted on the left hand side of the apron.
IN column 1: millimeter pitches to be cut.
27T, 28T, 30T: The number of teeth in "pitch-off gear" arranged to mesh with the leadscrew (this
being selected from the stack, stored on the bottom of the dial spindle)
Dial graduation:
The dial numbers at which the half nut may be engaged under numbers of teeth of pick- off gear.
Metric leadscrew machines (Metric thread only).the table shows:
Imperial leadscrew machines ( imperial thread only). The table shows:
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Instructions Manual for AL-356 (L564D)
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8. ELECTRIC CIRCUIT CONTROL
9.CHUCKS AND CHUCK MOUNTING
When fitting chucks or faceplates, first ensure that spindle and chuck tapers are be necessary
when mounting a new chuck to re-set the cam lock studs (A). to do this, remove the cap-head locking
screws (B) and set each stud so that the scribed ring (C) is flush with the rear face of the chuck-with the
slot lining up with the locking screw hole.
Now mount the chuck or faceplate on the spindle nose and tighten the six cams in turn. When fully
tightened, the cam lock line on each cam should be between the two V marks on the spindle nose.
If any of the cams do not tighten fully within these limit marks, remove the chuck or faceplate and
re-adjust the stud as indicated in the illustration. Fit and tighten the locking screw (B) at each stud
before remounting the chuck for work. A reference mark should be made on each correctly fitted chuck
or faceplate to coincide with the reference mark scribed in the spindle nose.
This will assist subsequent remounting. Do not interchange chucks or faceplate between lathes
without checking for correct cam locking.
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Instructions Manual for AL-356 (L564D)
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10.MAINTENANCES AND SERVICING
10-1. Lathe alignment
When the lathe is installed and ready for use,
it is recommended to check the machine
alignment before commencing work.
Alignment and leveling should be checked
regularly to insure continued accuracy.
Adopt this procedure as follow: take a steel
bar with a diameter of appr. 50mm and length of
appr. 200mm. span it in the chuck without using
the center. Then cut off a chip over a length of
150mm and measure the difference in A and B.
In order to correct a possible difference, loosen the screw (J) clamping the headstock on the bed.
Adjust the headstock with setscrew (s). repeat the above procedure until all measuring is correct. The
lathe will be cutting correctly.
10-2. Saddle strip
Wear on the rear saddle gig strip may be
accommodated by adjustment of the socket head set
screws.
The procedure for adjustment is to first take off the
rear splash guard (when fitted), release the hexagon
nuts and turn the socket head set screws slightly in
clockwise and the re-clomp the hexagon nuts. Care
should be taken to avoid over adjustment, α45°turn at the socket head set screw approximately
0.125(0.005”) take up in the gibe.
10-3. Cross slide
Wear on the taper-gibe strip may be adjusted for by
clockwise rotation of the slotted head screw on the
front face of the cross slide. The procedure is to first
slacken the similar screw at the rear then retighten
this after adjustment to clamp the gibe in its new
position.
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Instructions Manual for AL-356 (L564D)
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10-4. Compound rest
It is the same procedure as cross slide. To take up for
wear on the compound rest taper gibe strip can adjust
the slotted head screw on the tool post side of the
compound rest by clockwise rotation. The procedure
is to first slacken the similar screw at the opposite
side then re-tighten this after adjustment to clamp the
gibe in its new position.
10-5. Cross slide nut
Provision is made for the elimination of backlash in
the cross slide nut, the procedure for adjustment
being as follows: take off the dust plate which is
mounted on the rear face of saddle groove, turn the
cross feed nut until it reaches the and edge of the
feed rod. Turn the socket head cap screw in a
clockwise direction as required. Care should be taken
to avoid over adjustment, α45°turn at the socket head
capscrew represents approximately 0.125(0.005”)
take up of back lash.
10-6. Tailstock bed clamp
The angular lock position of the bed clamp lever is
adjusted by means of the self-locking hexagon
headed bolt located on the underside of the tailstock
and between the bed ways.
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Instructions Manual for AL-356 (L564D)
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Instructions Manual for AL-356 (L564D)
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BED ASSEMBLY (1/2)
№Part №Name Specification
1 V-Belt □A838/□A850/□A864
D330A-11106 50Hz
2 D330A-11106-1 PULLEY 60Hz
3 GB1096 KEY 8×35
4 GB5781 hexagon(al) head tap bolt M8×25
5 GB97.1 washer 8
6 motor 240v/380v/400v-50Hz-1.5Kw
7 GB78 screw M6×8
8 GB70 SOCKET HEAD SCREW M8×30
9 GB5781 hexagon(al) head tap bolt M8×40
9a GB6170 NUT M8
10 GB70 SOCKET HEAD SCREW M12×35
11 GB97.1 washer 12
12 GB5781 hexagon(al) head tap bolt M12×40
13 D330B-11107G BRACKET
14 GB5781 hexagon(al) head tap bolt M10×30
15 GB70 SOCKET HEAD SCREW M10×35
16 GB70 SOCKET HEAD SCREW M12×40
17 GB881 assembling pin 8×70
18 D330B-11103G BRIDGE
19 D330B-11101G BED
20 GB70 SOCKET HEAD SCREW M8×50
21 GB70 SOCKET HEAD SCREW M8×30
22 GB118 TAPER PIN 6×30
23 GB879 SPRING PIN 4×42
24 GB879 SPRING PIN 4×32
25 D330B-11203G CONTROL ROD
26 D330B-11202G FEED ROD
D330B-11201G Tr22×4-7h
27 D330B-11201G-1 LEADSCREW Tr22×3.175-7h
28 GB879 SPRING PIN 5×20
29 GB70 SOCKET HEAD SCREW M6×16
30 D330B-11205G SHORT RACK
31 D330B-11204G LONG RACK
32 GB1096 Oriented key 4×50
33 D330B-11217G COLLAR
34 GB77 SCREW M8×8
35 spring 6×1×15
36 D330B-11105G-1 ASSEMBLING PIN
37 SPRING 32×3.6×50
38 D330B-11105G BRACKET
39 GB879 SPRING PIN 5×20
40 knob BM10×32
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Instructions Manual for AL-356 (L564D)
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BED ASSEMBLY (1/2)
№Part №Name Specification
41 D330B-11206G LEVER
42 GB879 SPRING PIN 4×20
43 D330B-11104G BRACKET
44 GB78 SCREW M6×16
45 GB6170 NUT M6
46 GB118 TAPER PIN 6×45
47 GB7940.4 OIL CUP 6
48 GB70 SOCKET HEAD SCREW M8×60
49 GB78 SCREW M8×12
50 D330C-3012C PLECTRUM
51 GB70 SOCKET HEAD SCREW M8×16
52 GB818 SCREW M4×42
53a switch
53 D330C-11301C BOX
54 D330C-11302C COVER
55 GB818 SCREW M4×10
56 D330B-11210G-1 COVER 19
57 D330B-11210G-2 COVER 22
58 GB5781 HEXAGON HEAD TAP BOLT M12×45
59 GB97.1 WASHER 12
60 GB70 SOCKET HEAD SCREW M10×35
61 GB6170 NUT M10
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Instructions Manual for AL-356 (L564D)
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Instructions Manual for AL-356 (L564D)
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BED ASSEMBLY (2/2-1)
№Part №Name Specification
1 GB70 Socket head screw M6×12
2 GB97.1 Tailor-made washer 6
3 D330B-14205 Splash guard
4 GB818 screw M5×8
5 GB818 screw M4×28
6 GB91 pin 3×16
7 D330B-14214 Connecting rod
8 GB879 Spring pin 5×25
9 D330A-71205 backstop
10 D330A-21231 rocker
11 D330A-21230 shaft
12 D330A-21239 pin
13 Brake block Φ105×25(XF-125)
14 D330A-21105 pulley
15 GB97.1 washer 8
16 GB70 Socket head screw M8×16
16a GB1096 key 8×20
17 GB894.1 circlip 8
18 D330A-11232 shaft
19 D330B-14203 Oil tray
20 D330B-14204 Oil tray
24 GB70 Socket head screw M10×30
25 GB6170 Hexagon nut M10
26 GB70 Socket head screw M6×10
27 D330B-14201 Casting left stand
28 D330B-14210 cover
29 GB818 screw M5×12
30 D330B-14209 cover
31 D330A-11237 drawspring
32 D330A-11236 pin
33 D330A-11242 shaft
34 GB70 Socket head screw M6×40
35 GB879 Spring pin 5×40
36 D330A-11235 rocker
37 D330A-11238 Long shaft
38 D330B-14206 Angle iron
39 GB6170 Hexagon nut M6
40 GB97.1 Tailor-made washer 6
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Instructions Manual for AL-356 (L564D)
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BED ASSEMBLY (2/2-1)
№Part №Name Specification
41 GB70 Socket head screw M6×12
42 GB879 SPRING PIN 5×28
43 D330B-14207 Baffle board
44 D330B-14212 Brake pedal
45 D330A-11241 Short shaft
46 D330B-14202 Casting right stand
47 D330B-14208 cover
48 D330B-14213 funnel
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Instructions Manual for AL-356 (L564D)
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