OPTIMUM Maschinen OPTIturn TX 4414 User manual

GB
Operating Manual
Version 1.0.5
Lathe
Part no. 3432420

Version 1.0.5 - 2020-12-092 Translation of original instructions
TX4414
EN
TX4414_GBIVZ.fm
Table of contents
1 Safety
1.1 Rating plate................................................................................................................................................... 7
1.2 Safety instructions (warning notes)............................................................................................................... 8
1.2.1 Classification of hazards ................................................................................................................... 8
1.2.2 Other pictograms............................................................................................................................... 8
1.3 Intended use ................................................................................................................................................. 9
1.4 Reasonably foreseeable misuses............................................................................................................... 10
1.4.1 Avoiding misuse .............................................................................................................................. 10
1.5 Potential dangers that can be caused by the lathe..................................................................................... 10
1.6 Qualification of personnel ........................................................................................................................... 11
1.6.1 Target group.................................................................................................................................... 11
1.6.2 Authorized persons ......................................................................................................................... 12
1.6.3 Obligations of the operating company............................................................................................. 12
1.6.4 User's obligations ............................................................................................................................ 12
1.6.5 Additional requirements regarding the qualification ........................................................................12
1.7 Operator positions ...................................................................................................................................... 13
1.8 Safety measures during operation.............................................................................................................. 13
1.9 Safety devices ............................................................................................................................................ 13
1.9.1 Lockable master switch ................................................................................................................... 14
1.9.2 Emergency-stop button ................................................................................................................... 14
1.9.3 Protective cover of the headstock ................................................................................................... 14
1.9.4 Protective covers of drive ................................................................................................................ 14
1.9.5 Lathe chuck protection with position switch .................................................................................... 14
1.9.6 Chip guard shield ............................................................................................................................ 15
1.9.7 Prohibition, warning and mandatory signs ...................................................................................... 15
1.10 Safety check ............................................................................................................................................... 15
1.11 Personal protective equipment ................................................................................................................... 17
1.12 Safety during operation............................................................................................................................... 17
1.13 Safety during maintenance......................................................................................................................... 18
1.13.1 Disconnecting and securing the lathe ............................................................................................. 18
1.13.2 Using lifting equipment .................................................................................................................... 18
1.13.3 Mechanical maintenance work ........................................................................................................ 18
1.14 Accident report............................................................................................................................................ 18
1.15 Electronics .................................................................................................................................................. 19
1.16 Inspection deadlines................................................................................................................................... 19
2 Technical specification
2.1 Electrical connection................................................................................................................................... 20
2.2 Power.......................................................................................................................................................... 20
2.3 Work areas ................................................................................................................................................. 20
2.4 Work area ................................................................................................................................................... 20
2.5 Headstock................................................................................................................................................... 20
2.6 Lathe chuck ................................................................................................................................................ 20
2.7 Slides.......................................................................................................................................................... 20
2.8 Feeds and pitches ...................................................................................................................................... 20
2.15 Emissions ................................................................................................................................................... 21
2.9 Tailstock MT4 ............................................................................................................................................. 21
2.10 Tailstock MT5 version................................................................................................................................. 21
2.11 Steady rest, follow rest (option) .................................................................................................................. 21
2.12 Dimensions................................................................................................................................................. 21
2.13 Environmental conditions............................................................................................................................ 21
2.14 Operating material ...................................................................................................................................... 21

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3 Delivery, interdepartmental transport, assembly and commissioning
3.1 Notes on transport, installation, commissioning ..........................................................................................23
3.1.1 General risks during internal transport.............................................................................................23
3.2 Delivery .......................................................................................................................................................24
3.3 Unpacking ...................................................................................................................................................24
3.4 Lifting the machine ......................................................................................................................................24
3.4.1 Forklift ..............................................................................................................................................24
3.4.2 Crane ...............................................................................................................................................25
3.5 Installation conditions ..................................................................................................................................26
3.5.1 Foundation and floor ........................................................................................................................26
3.5.2 Local requirements for delivery........................................................................................................26
3.5.3 Installation plan ................................................................................................................................27
3.6 Assembly and installation, initial operation..................................................................................................27
3.6.1 Anchor-free assembly ......................................................................................................................28
3.6.2 Installation with levelling- damping elements...................................................................................28
3.6.3 Installation with vibration dampers...................................................................................................28
3.6.4 Anchored assembly..........................................................................................................................30
3.6.5 Aligning the machine........................................................................................................................31
3.7 Cleaning the machine..................................................................................................................................32
3.7.1 Lubrication........................................................................................................................................32
3.8 One-component paint..................................................................................................................................32
3.9 Electrical connection ...................................................................................................................................33
3.10 Start and stop spindle rotation.....................................................................................................................33
3.11 Warming up the machine ............................................................................................................................33
4Operation
4.1 Control and indicating elements ..................................................................................................................34
4.2 Safety ..........................................................................................................................................................35
4.3 Switching on the machine ...........................................................................................................................35
4.4 Switching off the machine ...........................................................................................................................35
4.5 Resetting an emergency stop condition ......................................................................................................35
4.6 Power failure, Restoring readiness for operation ........................................................................................35
4.7 Foot brake ...................................................................................................................................................35
4.8 Speed setting ..............................................................................................................................................35
4.8.1 Rotational direction ..........................................................................................................................36
4.9 Feed ............................................................................................................................................................37
4.9.1 Bed slide and cross slide rapid traverse ..........................................................................................38
4.10 Spindle seat Camlock DIN ISO 702-2 .........................................................................................................38
4.10.1 Fasten workpiece holder..................................................................................................................38
4.10.2 Adjusting the Camlock bolts to the workpiece holder.......................................................................39
4.11 Lathe chuck .................................................................................................................................................39
4.11.1 Speed information, maintenance recommendations, reference speed in accordance with DIN 6386.
40
4.11.2 Influencing factors that significantly impact the tensioning force .....................................................40
4.11.3 Maintenance of chucks ....................................................................................................................41
4.12 Clamping a workpiece into the lathe chuck .................................................................................................41
4.12.1 Clamping long workpieces ...............................................................................................................43
4.13 Mounting workpiece holder .........................................................................................................................44
4.13.1 Centering point in lathe spindle........................................................................................................44
4.14 Mounting of rests.........................................................................................................................................44
4.14.1 Follow rest and steady rest ..............................................................................................................44
4.15 General operating instructions ....................................................................................................................44
4.15.1 Longitudinal turning..........................................................................................................................44
4.15.2 Face turning and recessing..............................................................................................................45
4.15.3 Fixing the lathe saddle .....................................................................................................................45

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4.15.4 Tailstock .......................................................................................................................................... 45
4.16 Manual movements .................................................................................................................................... 45
4.17 Automatic feed............................................................................................................................................ 46
4.17.1 Straight turning ................................................................................................................................ 46
4.17.2 Face turning .................................................................................................................................... 47
4.18 Turning tapers............................................................................................................................................. 47
4.18.1 Cross-adjustment of the tailstock .................................................................................................... 47
4.18.2 Turning short tapers with the top slide ............................................................................................ 48
4.18.3 Turning of cones with high precision ............................................................................................... 48
4.19 Displacing the top slide on the cross slide.................................................................................................. 51
4.20 Standard values for cutting data when turning ........................................................................................... 51
4.21 Thread cutting............................................................................................................................................. 52
4.21.1 Module and D.P. threads................................................................................................................. 52
4.21.2 Thread cutting ................................................................................................................................. 52
4.21.3 Multiple-layered threads .................................................................................................................. 54
4.21.4 Thread types ................................................................................................................................... 54
4.21.5 Metric threads (60° flank angle) ...................................................................................................... 56
4.21.6 British thread (55° flank angle)........................................................................................................ 57
4.21.7 Indexable inserts ............................................................................................................................. 59
4.22 Cooling lubricant ......................................................................................................................................... 60
4.22.1 Cooling lubricants............................................................................................................................ 60
4.23 DP700 Quick start guide............................................................................................................................. 62
4.24 NMS 300 Quick start guide......................................................................................................................... 65
5 Cutting speeds
5.1 Selecting the cutting speed......................................................................................................................... 68
5.2 Influences on the cutting speed.................................................................................................................. 68
5.3 Example for the determination of the required speed on your lathe ........................................................... 68
5.4 Table cutting speeds................................................................................................................................... 69
6 Maintenance
6.1 Safety.......................................................................................................................................................... 70
6.1.1 Preparation...................................................................................................................................... 70
6.1.2 Restarting ........................................................................................................................................ 71
6.2 Inspection and maintenance....................................................................................................................... 71
6.3 Recommended wearing parts..................................................................................................................... 75
6.4 Maintenance ............................................................................................................................................... 76
6.4.1 Tensioning of drive belt ................................................................................................................... 76
6.4.2 Refilling the cooling lubricant........................................................................................................... 76
6.4.3 Replacement of the shear pin on the feed rod ................................................................................ 76
6.4.4 Adjusting the spindle nut on the top slide........................................................................................ 77
6.4.5 Adjusting the spindle nut on the cross slide .................................................................................... 78
6.4.6 Adjusting the tapered gibs on the top slide and cross slide ............................................................ 78
6.4.7 Lathe saddle.................................................................................................................................... 78
6.4.8 Apron............................................................................................................................................... 78
6.4.9 Feed rod, Lead screw...................................................................................................................... 79
6.4.10 Lubricating and cleaning the lathe chuck ........................................................................................ 79
6.4.11 Cleaning the electrical cabinet ........................................................................................................ 79
6.4.12 Aligning the headstock .................................................................................................................... 80
6.5 Repair ......................................................................................................................................................... 81
6.5.1 Customer service technician ........................................................................................................... 81
6.6 Cooling lubricants and tanks....................................................................................................................... 82
6.6.1 Inspection plan for water-mixed cooling lubricants.......................................................................... 83
7 Rotary chuck - K11-200 ISO 702-2
7.1 Safety instructions ...................................................................................................................................... 85
7.2 Intended use ............................................................................................................................................... 85
7.3 Reasonably foreseeable misuses............................................................................................................... 85

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7.3.1 Avoiding misuse...............................................................................................................................85
7.4 Basic safety instructions..............................................................................................................................86
7.4.1 Optional soft lathe chuck jaws..........................................................................................................86
7.5 Calculating the required clamping force for a given speed .........................................................................87
7.6 Clamping force-speed diagram - Lathe chuck K11-200 ..............................................................................88
7.7 Clamping jaw centrifugal force ....................................................................................................................88
7.8 Notes on instruction of operating personnel................................................................................................90
7.9 Scope of delivery.........................................................................................................................................90
7.10 Assembly.....................................................................................................................................................91
7.11 Assembly of the manual chuck....................................................................................................................91
7.11.1 Handling before mounting................................................................................................................91
7.11.2 Preparing the chuck attachment ......................................................................................................91
7.11.3 Mounting of the manual chuck .........................................................................................................91
7.12 Lubricating and cleaning the lathe chuck ....................................................................................................91
8 Ersatzteile - Spare parts
8.1 Ersatzteilbestellung - Ordering spare parts .................................................................................................92
8.2 Hotline Ersatzteile - Spare parts Hotline .....................................................................................................92
8.3 Service Hotline ............................................................................................................................................92
8.4 Ersatzteilzeichnungen - Spare part drawings..............................................................................................93
A Spindelgetriebe - Spindle gear.........................................................................................................93
B Spindelgetriebe - Spindle gear.........................................................................................................94
C Spindelgetriebe - Spindle gear.........................................................................................................95
D Spindelgetriebe - Spindle gear.........................................................................................................96
E Vorschubgetriebe - Feed gear .......................................................................................................100
F Vorschubgetriebe - Feed gear .......................................................................................................101
G Vorschubgetriebe - Feed gear .......................................................................................................102
H Schlosskasten Handrad links - Apron hand wheel left side ...........................................................106
I Planschlitten, Bettschlitten - Cross slide, bed slide........................................................................109
J Oberschlitten - Top slide ...............................................................................................................111
K Maschinenbett kurz mit Bettbrücke - Short machine bed with bed bridge ....................................113
U Maschinenbett lang ohne Bettbrücke - Long machine bed without bed bridge.............................114
L Maschinenbett - Machine bed........................................................................................................115
M Maschinenbett - Machine bed........................................................................................................116
N Reitstock - Tailstock.......................................................................................................................118
O Drehfutterschutz - Lathe chuck protection .....................................................................................120
P Mitlaufende Lünette - Follow rest...................................................................................................121
Q Feststehende Lünette - Steady rest ...............................................................................................122
R Schaltplan - Wiring diagram...........................................................................................................123
S Schaltplan - Wiring diagram...........................................................................................................124
T Schaltplan - Wiring diagram...........................................................................................................125
9 Malfunctions
10 Appendix
10.1 Copyright ...................................................................................................................................................131
10.2 Terminology/Glossary ...............................................................................................................................131
10.3 Change information operating manual ......................................................................................................131
10.4 Liability claims/warranty ............................................................................................................................132
10.5 Storage......................................................................................................................................................133
10.6 Dismantling, disassembling, packing and loading.....................................................................................133
10.6.1 Decommissioning...........................................................................................................................134
10.6.2 Dismantling ....................................................................................................................................134
10.6.3 Disassembly...................................................................................................................................134
10.6.4 Packing and loading.......................................................................................................................134
10.7 Disposal of new device packaging ............................................................................................................134
10.8 Disposal of lubricants and cooling lubricants ............................................................................................134
10.9 Disposal via municipal collection facilities .................................................................................................135
10.10 Product follow-up.......................................................................................................................................135
The operating instructions for the DP700 digital display can be downloaded from the manufacturer's website
in different languages. http://www.newall.co.uk/support/downloads/digital_readouts/

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Preface
Dear customer,
Thank you very much for purchasing a product made by OPTIMUM.
OPTIMUM metal working machines offer a maximum of quality, technically optimum solutions
and convince by an outstanding price performance ratio. Continuous enhancements and prod-
uct innovations guarantee state-of-the-art products and safety at any time.
Before commissioning the machine please thoroughly read these operating instructions and get
familiar with the machine. Please also make sure that all persons operating the machine have
read and understood the operating instructions beforehand. 
Keep these operating instructions in a safe place nearby the machine.
Information
The operating instructions include indications for safety-relevant and proper installation, opera-
tion and maintenance of the machine. The continuous observance of all notes included in this
manual guarantee the safety of persons and of the machine.
The manual determines the intended use of the machine and includes all necessary information
for its economic operation as well as its long service life.
In the paragraph "Maintenance" all maintenance works and functional tests are described which
the operator must perform in regular intervals.
The illustration and information included in the present manual can possibly deviate from the
current state of construction of your machine. Being the manufacturer we are continuously
seeking for improvements and renewal of the products. Therefore, changes might be performed
without prior notice. The illustrations of the machine may be different from the illustrations in
these instructions with regard to a few details. However, this does not have any influence on
the operability of the machine. 
Therefore, no claims may be derived from the indications and descriptions. Changes and errors
are reserved!
Your suggestion with regard to these operating instructions are an important contribution to
optimising our work which we offer to our customers. For any questions or suggestions for
improvement, please do not hesitate to contact our service department.
If you have any further questions after reading these operating instructions and you are
not able to solve your problem with a help of these operating instructions, please
contact your specialised dealer or directly the company OPTIMUM.
Optimum Maschinen Germany GmbH
Dr.- Robert - Pfleger - Str. 26
D-96103 Hallstadt
Fax (+49)0951 / 96555 - 888
email: [email protected]
Internet: www.optimum-maschinen.de

Safety
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1 Safety
Glossary of symbols
This part of the operating instructions
explains the meaning and use of the warning notes included in these operating instructions,
defines the intended use of the lathe,
points out the dangers that might arise for you or others if these instructions are not
observed,
informs you about how to avoid dangers.
In addition to these operating instructions, please observe
the applicable laws and regulations,
the statutory provisions for accident prevention,
the prohibition, warning and mandatory signs as well as the warning notes on the lathe.
European standards must be observed during the installation, operation, maintenance and
repair of the lathe.
If European standards have not yet been incorporated in the national legislation of the country
of destination, the specific applicable regulations of each country must be observed.
If applicable, necessary measures must be taken to comply with the country-specific regula-
tions before commissioning the lathe.
Always keep this documentation close to the lathe.
If you would like to order another operating manual for your machine, please indicate the serial
number of your machine. The serial number is located on the type plate.
INFORMATION
If you are unable to rectify an issue using these operating instructions, please contact us for
advice:
Optimum Maschinen Germany GmbH
Dr.-Robert-Pfleger-Str. 26
D-96103 Hallstadt
Email: [e-mail]
1.1 Rating plate
provides further instructions
calls on you to act
listings
DE Drehmaschine
EN Lathe
FR Tour
ES Torno
IT Tornio
CS Soustruh
DA Drehbænk
EL Tόρνος
FI Kärkisorvi
HU Esztergapad
NL Draaibank
PL Tokark a
PT Torno
RO Strung
RU Токар ный с танок
SK Sústruh
SL Stružnica
SV Svarv
TR Torna Tezgahı
TX 4414
NO
SN
Year
Netto
5,5 KW
400 V ~50 Hz
2.200 min.
-1
3432420
2.100 kg
www.optimum-maschinen.de
Optimum Maschinen
Germany GmbH
Dr.-Robert-Pfleger-Str. 26
96103 Hallstadt / Deutschland

Safety
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1.2 Safety instructions (warning notes)
1.2.1 Classification of hazards
We classify the safety warnings into different categories. The table below gives an overview of
the classification of symbols (ideogram) and the warning signs for each specific danger and its
(possible) consequences.
1.2.2 Other pictograms
Symbol Alarm expression Definition / consequence
DANGER! Impending danger that will cause serious injury or death to people.
WARNING! A danger that can cause serious injury or death.
CAUTION! A danger or unsafe procedure that can cause personal injury or damage
to property.
ATTENTION!
Situation that could cause damage to the lathe and the product and other
types of damage.
No risk of injury to persons.
INFORMATION
Practical tips and other important or useful information and notes.
No dangerous or harmful consequences for people or objects.
In case of specific dangers, we replace the pictogram with
or
general danger with a warning of injuries to
hands,
hazardous
electrical voltage,
rotating parts.
Warning: danger of
slipping!
Warning: risk of stumbling! Warning: hot surface! Warning: biological hazard!
Warning: automatic start-
up!
Warning: tilting danger! Warning: suspended loads! Caution, danger of
explosive substances!

Safety
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1.3 Intended use
WARNING!
Improper use of the lathe will result in
will endanger personnel,
will endanger the lathe and other material property of the operator,
the correct function of the lathe may be affected.
The lathe was constructed for the longitudinal and face turning of round or regularly shaped
workpieces of cold metal with a diameter and weight within the limits of the specified technical
data. The lathe must only be installed and operated in a dry and ventilated place. The machine
integrated coolant system is only intended for water-miscible cooling lubricants.
The lathe is designed and manufactured to be used in environments where there is no poten-
tial danger of explosion.
If the lathe is used in any way other than described above, or modified without the approval of
Maschinen Germany GmbH, then the lathe is being used improperly.
We will not be held liable for any damages resulting from any operation which is not in accord-
ance with the intended use.
We expressly point out that the guarantee will expire, if any constructive, technical or proce-
dural changes are not performed by the company Optimum Maschinen Germany GmbH.
It is also part of the intended use that you
observe the limits of the lathe,
observe the operating instructions,
and comply with the inspection and maintenance instructions.
 Technical specification on page 20
In order to achieve optimum cutting performance, it is essential to choose the right turning tool,
feed, tool pressure, cutting speed and coolant.
WARNING!
Severe injuries due to non-intended use.
Switching on forbidden! Do not climb onto the
machine!
Read the operating
instructions before
commissioning!
Pull out the mains plug!
Wear protective glasses! Wear protective gloves! Wear safety shoes! Wear a protective suit!
Use ear protection! Only switch when stopped! Protect the environment! Contact address

Safety
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It is forbidden to make any modifications or alternations to the operation values of the
lathe. They could endanger the personnel and cause damage to the lathe.
1.4 Reasonably foreseeable misuses
Any other use other than that specified under "Intended use" or any use beyond the described
use shall be deemed as non-intended use and is not permissible.
Any other use has to be discussed with the manufacturer.
It is only permissible to process metal, cold and non-inflammable materials with the lathe.
In order to avoid misuse, it is necessary to read and understand the operating instructions
before the first commissioning.
The operators must be qualified.
1.4.1 Avoiding misuse
Use of suitable cutting tools.
The operating speed of the lathe may not exceed the permissible speed of the used clamp-
ing device.
Adapting the speed adjustment and feed to the material and workpiece.
Insert the workpiece tightly, without vibration and without one-sided imbalances.
The machine is not designed for the use of hand tools (e.g. emery cloth or files). It is forbid-
den to use any hand tools on this machine.
The machine is not designed to allow long parts to protrude beyond the spindle hole. If
longer parts have to protrude beyond the spindle hole, an additional operator-side, perma-
nent device must be mounted, which completely covers the protruding part and provides
complete protection against spinning parts.
Long workpieces must be propped up. Use the steady rest or follow rest in conjunction with
the tailstock spindle to support longer parts and prevent the workpiece from flapping around
and flying away.
Risk of fire and explosion due to the use of flammable materials or cooling lubricants.
Before processing inflammable materials (e.g. aluminium, magnesium) or using inflamma-
ble auxiliary materials (e.g. spirit), it is necessary to take additional preventive measures in
order to avoid health risks.
When processing carbons, graphite and carbon-fibre-reinforced carbons, the machine is no
longer being used as intended. When processing carbons, graphite and carbon-fibre-rein-
forced carbons and similar materials, the machine can be damaged quickly, even if the
dusts generated are completely sucked out during the work process.
The processing of plastics with the lathe leads to static charge. The static charge of
machine parts from processing plastics cannot be safely conducted away from the lathe.
When using lathe dogs as carriers for rotating workpieces between the lathe centres, the
standard lathe chuck shield must be replaced with a circular lathe chuck shield.
1.5 Potential dangers that can be caused by the lathe
The lathe has been tested for operational safety. The construction and type are state of the art.
Nevertheless, there is a residual risk as the lathe operates with
high revolutions,
with rotating parts,
electrical voltage and currents,
We have used design and safety engineering to minimize the health risk to personnel resulting
from these hazards.
If the lathe is used and maintained by personnel who are not duly qualified, there may be a risk
resulting from incorrect or unsuitable maintenance of the lathe.