Optimum PPTiturn TH 3309 User manual

EN
Operating Manual
Version 1.1.0
Lathe
Part no. 3402030
3402040
TH3309D

Version 1.1.0 - 2020-08-062 Translation of original instruction
TH3309 | TH3309D
EN
TH3309_TH3309D_GBIVZ.fm
Table of contents
1 Safety
1.1 Rating plates.............................................................................................................................................7
1.2 Safety instructions (warning notes)...........................................................................................................8
1.2.1 Classification of hazards...........................................................................................................................8
1.2.2 Pictograms................................................................................................................................................8
1.3 Intended use .............................................................................................................................................9
1.4 Reasonably foreseeable misuse.............................................................................................................10
1.4.1 Avoiding misuse......................................................................................................................................10
1.5 Potential dangers that can be caused by the lathe.................................................................................11
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................................................................................13
1.7 User positions .........................................................................................................................................13
1.8 Safety measures during operation..........................................................................................................13
1.9 Safety devices ........................................................................................................................................13
1.9.1 Lockable main switch..............................................................................................................................14
1.9.2 Emergency stop button...........................................................................................................................15
1.9.3 Protective cover with interlock switch .....................................................................................................15
1.9.4 Lathe chuck protection with position switch............................................................................................16
1.9.5 Chip shield..............................................................................................................................................16
1.9.6 Protective cover on the lead screw.........................................................................................................17
1.9.7 Prohibition, warning and mandatory signs..............................................................................................17
1.10 Safety check ...........................................................................................................................................17
1.11 Personnel protective equipment .............................................................................................................18
1.12 For your own safety during operation .....................................................................................................18
1.13 Safety during maintenance.....................................................................................................................19
1.13.1 Disconnecting and securing the lathe.....................................................................................................19
1.13.2 Using lifting equipment ...........................................................................................................................19
1.13.3 Mechanical maintenance work ...............................................................................................................19
1.14 Accident report........................................................................................................................................20
1.15 Electrical system.....................................................................................................................................20
1.16 Inspection deadlines...............................................................................................................................20
2 Technical specification
2.1 Electrical connection...............................................................................................................................21
2.2 Drive motor power ..................................................................................................................................21
2.3 Work areas .............................................................................................................................................21
2.4 Headstock...............................................................................................................................................21
2.5 Feeds and pitches ..................................................................................................................................21
2.6 Slides......................................................................................................................................................21
2.7 Tailstock..................................................................................................................................................22
2.8 Steady and follow rest ............................................................................................................................22
2.9 Work area, weights .................................................................................................................................22
2.10 Environmental conditions........................................................................................................................22
2.11 Operating material ..................................................................................................................................22
2.12 Emissions ...............................................................................................................................................23
2.13 Dimensions, installation plan ..................................................................................................................24
3 Delivery, interdepartmental transport, assembly and commissioning
3.1 Notes on transport, installation, commissioning .....................................................................................26
3.1.1 General risks during internal transport....................................................................................................26

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3.2 Assembly................................................................................................................................................ 27
3.3 Unpacking the machine.......................................................................................................................... 27
3.4 Scope of delivery.................................................................................................................................... 27
3.5 Transport ................................................................................................................................................ 27
3.5.1 Load suspension point ........................................................................................................................... 27
3.5.2 Gravity of the machine ........................................................................................................................... 27
3.5.3 Lifting with a forklift................................................................................................................................. 28
3.5.4 Lifting by crane....................................................................................................................................... 29
3.6 Installation and assembly ....................................................................................................................... 30
3.6.1 Requirements regarding the installation site .......................................................................................... 30
3.7 Cleaning the machine............................................................................................................................. 30
3.7.1 Lubrication.............................................................................................................................................. 31
3.8 Anchor-free assembly ............................................................................................................................ 31
3.8.1 Dimension of vibration damper............................................................................................................... 31
3.9 Anchored assembly................................................................................................................................ 32
3.10 First commissioning................................................................................................................................ 32
3.11 Electric three-phase connection............................................................................................................. 32
3.12 Warming up the machine ....................................................................................................................... 33
3.13 Functional check .................................................................................................................................... 33
3.14 Start and stop spindle rotation................................................................................................................ 33
3.15 Warming up the machine ....................................................................................................................... 33
4Operation
4.1 Control and indicating elements ............................................................................................................. 34
4.2 Safety ..................................................................................................................................................... 35
4.2.1 Overview of the control elements ........................................................................................................... 35
4.2.2 Control elements .................................................................................................................................... 36
4.3 Switching the machine on ...................................................................................................................... 36
4.4 Switching the machine off ...................................................................................................................... 36
4.5 Resetting an emergency stop condition ................................................................................................. 37
4.6 Power failure, Restoring readiness for operation ................................................................................... 37
4.7 Momentary switch, direct run ................................................................................................................. 37
4.8 Foot brake .............................................................................................................................................. 37
4.9 Speed setting ......................................................................................................................................... 37
4.9.1 Speed table TH3309 | TH3309D ............................................................................................................ 37
4.9.2 Position change of the V-belt package................................................................................................... 38
4.10 Turning direction..................................................................................................................................... 39
4.11 Feed ....................................................................................................................................................... 39
4.11.1 Infeed speed........................................................................................................................................... 39
4.11.2 Feed direction......................................................................................................................................... 39
4.12 Tool holder ............................................................................................................................................. 40
4.13 Lathe spindle fixture ............................................................................................................................... 41
4.13.1 Fasten workpiece holder ........................................................................................................................ 42
4.13.2 Lathe chuck ............................................................................................................................................ 42
4.13.3 Speed information, maintenance recommendations, reference speed in accordance with DIN 6386 ... 43
4.13.4 Influencing factors that significantly impact the tensioning force............................................................ 43
4.13.5 Lathe chuck maintenance ...................................................................................................................... 44
4.13.6 Clamping long workpieces ..................................................................................................................... 44
4.13.7 Mounting workpiece holder .................................................................................................................... 45
4.14 Mounting of rests.................................................................................................................................... 45
4.14.1 Follow and steady rests.......................................................................................................................... 45
4.15 Bed insert ............................................................................................................................................... 46
4.16 Setting the feed ...................................................................................................................................... 47
4.17 Adjusting threads.................................................................................................................................... 48
4.17.1 Change gear table.................................................................................................................................. 49

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4.17.2 Exchange, change of position of the change gears................................................................................50
4.18 Tailstock..................................................................................................................................................51
4.18.1 Cross-adjustment of the tailstock............................................................................................................51
4.19 General operating instructions................................................................................................................52
4.19.1 Longitudinal turning ................................................................................................................................52
4.19.2 Face turning and recessing ....................................................................................................................52
4.19.3 Fixing the lathe saddle............................................................................................................................52
4.19.4 Turning between centres ........................................................................................................................53
4.19.5 Turning short tapers with the top slide....................................................................................................53
4.19.6 Thread cutting.........................................................................................................................................54
4.19.7 Cooling agent..........................................................................................................................................54
4.19.8 Cooling lubricants ...................................................................................................................................54
5 Cutting speeds
5.1 Selecting the cutting speed.....................................................................................................................56
5.2 Influences on the cutting speed..............................................................................................................56
5.3 Example for the determination of the required speed on your lathe .......................................................56
5.4 Table cutting speeds...............................................................................................................................57
6 Maintenance
6.1 Safety......................................................................................................................................................58
6.1.1 Preparation .............................................................................................................................................58
6.1.2 Restarting ...............................................................................................................................................58
6.1.3 Cleaning..................................................................................................................................................59
6.2 Check up, inspection and maintenance..................................................................................................59
6.3 Recommended wear and tears parts......................................................................................................65
6.4 Lubricating and cleaning the lathe chuck................................................................................................66
6.5 Repair .....................................................................................................................................................66
6.5.1 Customer service technician...................................................................................................................66
7 Ersatzteile - Spare parts
7.1 Ersatzteilbestellung - Ordering spare parts ............................................................................................67
7.2 Hotline Ersatzteile - Spare parts Hotline.................................................................................................67
7.3 Service Hotline........................................................................................................................................67
7.4 Elektrische Ersatzteile - Electrical spare parts........................................................................................67
7.5 Schaltplan - Wiring diagram....................................................................................................................67
7.6 Getriebe Spindelstock 1-6 - Headstock gear 1-6....................................................................................68
7.7 Getriebe Spindelstock 2-6 - Headstock gear 2-6....................................................................................69
7.8 Getriebe Spindelstock 3-6 - Headstock gear 3-6...................................................................................70
7.9 Getriebe Spindelstock 4-6 - Headstock gear 4-6...................................................................................71
7.10 Getriebe Spindelstock 5-6 - Headstock gear 5-6...................................................................................72
7.11 Getriebe Spindelstock 6-6 - Headstock gear 6-6...................................................................................73
7.12 Wechselradgetriebe - Change gear........................................................................................................74
7.13 Vorschubgetriebe 1-6 - Feed gear 1-6...................................................................................................74
7.14 Vorschubgetriebe 2-6 - Feed gear 2-6...................................................................................................75
7.15 Vorschubgetriebe 3-6 - Feed gear 3-6...................................................................................................76
7.16 Vorschubgetriebe 4-6 - Feed gear 4-6...................................................................................................77
7.17 Vorschubgetriebe 5-6 - Feed gear 5-6...................................................................................................78
7.18 Vorschubgetriebe 6-6 - Feed gear 6-6...................................................................................................79
7.19 Schlosskasten 1-3 - Apron 1-3 ..............................................................................................................80
7.20 Schlosskasten 2-3 - Apron 2-3 ...............................................................................................................81
7.21 Schlosskasten 3-3 - Apron 3-3 ..............................................................................................................82
7.22 Planschlitten - Cross slide ......................................................................................................................83
7.23 Oberschlitten - Top slide.........................................................................................................................84
7.24 Maschinenbett 1-2 - Lathe bed 1-2.........................................................................................................85
7.25 Maschinenbett 2-2 - Lathe bed 2-2.........................................................................................................86
7.26 Spindelbremse - Spindle break...............................................................................................................87

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7.27 Maschinenunterbau - Machine substructure .......................................................................................... 87
7.28 Reitstock - Tailstock ............................................................................................................................... 88
7.29 Feststehende Lünette - Steady rest ....................................................................................................... 89
7.30 Mitlaufende Lünette - Follow rest ........................................................................................................... 90
7.31 Drehfutterschutz - Chuck protection....................................................................................................... 91
7.32 Späneschutz - Chip protection ............................................................................................................... 92
7.33 Maschinenschilder - Machine labels ...................................................................................................... 93
7.34 Schaltplan - Wiring diagram - TH3309 │TH3309D - 400V, 1 - 2............................................................ 94
7.35 Schaltplan - Wiring diagram - TH3309 │TH3309D - 400V, 2 - 2............................................................ 95
7.36 Ersatzteilliste - Spare parts list ............................................................................................................... 96
8 Malfunctions
9 Appendix
9.1 Copyright .............................................................................................................................................. 114
9.2 Terminology/Glossary .......................................................................................................................... 114
9.3 Change information manual ................................................................................................................. 114
9.4 Liability claims/warranty ....................................................................................................................... 115
9.5 Storage................................................................................................................................................. 116
9.6 Dismantling, disassembling, packing and loading................................................................................ 116
9.6.1 Decommissioning ................................................................................................................................. 117
9.6.2 Dismantling........................................................................................................................................... 117
9.6.3 Disassembly ......................................................................................................................................... 117
9.6.4 Packing and loading ............................................................................................................................. 117
9.7 Disposal of new device packaging ....................................................................................................... 117
9.8 Disposal of lubricants and cooling lubricants ....................................................................................... 117
9.9 Disposal via municipal collection facilities ............................................................................................ 118
9.10 Product follow-up.................................................................................................................................. 118

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_preface_GB.fm
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 product 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, operation and main-
tenance 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 eco-
nomic 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 hesi-
tate 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
Mail: [e-mail]
Internet: www.optimum-maschinen.com

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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 operation 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.
1.1 Rating plates
provides further instructions
calls on you to act
listings
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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, Germany
Email: [e-mail]
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 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
injury to hands, hazardous electrical
voltage,
rotating parts.
Warning: danger of
slipping! Warning: risk of stumbling! Warning: hot surface! Warning: biological hazard!

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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 is designed and manufactured for longitudinal and straight turning of round and regu-
lar formed
workpieces in cold metal, their diameter and weight are within the limits of the given specifica-
tions. The lathe must only be installed and operated in a dry and ventilated place.
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 or CE conformity will expire, if any constructive, tech-
nical or procedural changes are not performed by the company Optimum Maschinen Germany
GmbH.
Warning: automatic start-
up!
Warning: tilting danger! Warning: suspended loads! Caution, danger of
explosive substances!
Switching on forbidden! Do not climb onto the
machine!
Do not clean with
compressed air!
Read the operating
instructions before
commissioning!
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

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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 21
In order to achieve optimum cutting performance, it is essential to choose the right turning tool,
feed, tool pressure, cutting speed and coolant.
1.4 Reasonably foreseeable misuse
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.
The lathe must not be used to process metal, cold and non-inflammable materials.
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.
Do not create in processing any continuous chips. Adjust the cutting speed when continu-
ous chips are produced. Adapting the speed adjustment and feed to the material and work-
piece.
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 suitable for attachment kits for cylindrical grinding. When mounting
attachment kits for cylindrical grinding, additional protective devices must be fitted.
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.

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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.
INFORMATION
Everyone involved in the assembly, commissioning, operation and maintenance must
be duly qualified,
and strictly follow these operating instructions.
In the event of improper use
there may be a risk to personnel,
there is a risk of damage to the lathe and other property,
the correct function of the lathe may be affected.
Always disconnect the lathe, when cleaning or maintenance work is being carried out.
WARNING!
The lathe may only be used with the safety devices activated.
Disconnect the lathe immediately whenever you detect a failure in the safety devices or
when they are not mounted!
All additional devices installed by the operator have to be equipped with the prescribed
safety devices.
As the operating company, this is your responsibility!
 Safety devices on page 13
1.6 Qualification of personnel
1.6.1 Target group
This manual is addressed to
the operating companies,
the operators,
the maintenance personnel.
Therefore, the warning notes refer to both the operation and maintenance of the lathe.
Determine and indicate clearly who will be responsible for the different activities on the lathe
(operation, maintenance and repair).
Unclear responsibilities constitute a safety risk!
Always disconnect the main plug of the lathe and secure the main switch using a lock. This will
prevent it from being used by unauthorized persons.
The qualifications of the personnel for the different tasks are mentioned below:
Operator
The operator is instructed by the operating company about the assigned tasks and possible
risks in case of improper behaviour. Any tasks performed beyond operation in standard mode

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may only be performed by an operator if they are described in these instructions and if the oper-
ator has been specifically trained to perform them by the operating company.
Qualified electrician
With professional training, knowledge and experience as well as knowledge of respective
standards and regulations, qualified electricians are able to perform work on the electrical sys-
tem and recognise and avoid any possible dangers.
Qualified electricians have been specially trained for the working environment, in which they are
working and know the relevant standards and regulations.
Qualified personnel
Due to their professional training, knowledge and experience as well as knowledge of relevant
regulations, qualified personnel are able to perform the assigned tasks and to independently
recognise and avoid any possible dangers.
Instructed person
Instructed persons were instructed by the operating company regarding the assigned tasks and
any possible risks of improper behaviour.
1.6.2 Authorized persons
WARNING!
Inappropriate operation and maintenance of the lathe constitutes a danger for the
personnel, objects and the environment.
Only authorized personnel may operate the lathe!
Persons authorized to operate and maintain should be trained technical personnel and
instructed by the ones who are working for the operating company and for the manufacturer.
1.6.3 Obligations of the operating company
The operator must instruct the personnel at least once a year regarding
all safety standards that apply to the lathe.
the operation,
generally accepted engineering standards.
The operating company must also
check the personnel‘s knowledge level,
document the training/instruction,
require personnel to confirm participation in training/instruction by means of a signature,
check whether the personnel is working in a safety and risk-conscious manner and follow-
ing the operating instructions.
Define and document the machine inspection deadlines in accordance with section 3 of the
Factory Safety Order and perform an operational risk analysis in accordance with section 6
of the Safety at Work Act.
1.6.4 User's obligations
The operator must
have read and understood the operating instructions,
be familiar with all safety devices and regulations,
be able to operate the lathe.

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1.6.5 Additional requirements regarding the qualification
Additional requirements apply for work on electrical components or equipment:
Must only be performed by a qualified electrician or person working under the instructions
and supervision of a qualifiedelectrician.
Before starting work on electrical parts or operating agents, following measures are to be
performed in the following order:
disconnect all poles,
secure against restarting,
Ensure that there is no voltage.
1.7 User positions
The operator position is in front of the lathe.
1.8 Safety measures during operation
CAUTION!
Danger due to inhaling dust and mist that is hazardous to health.
Dependent on the material which need to be processed and the used auxiliaries dusts
and mist may be caused which might impair you health.
Make sure that the generated health hazardous dusts and mist are safely sucked off at
the point of origin and is dissipated or filtered from the working area. To do so, use a
suitable extraction unit.
CAUTION!
Risk of fire and explosion by using flammable materials or cooling lubricants.
Before processing inflammable materials (e.g. aluminium, magnesium) or using
inflammable auxiliary materials (e.g. spirit) it is necessary to take additional preventive
measures in order to safely avoid health risks.
CAUTION!
Risk of becoming entangled or lacerations when using hand tools.
The machine is not designed for the use of hand tools (e.g. emery cloth or files). It is
forbidden to use any hand tools on this machine.
1.9 Safety devices
Use the lathe only with properly functioning safety devices.
Stop the lathe immediately if there is a failure on the safety device or if it is not functioning for
any reason.
It is your responsibility!
If a safety device has been deactivated or is defective, the lathe can only be used again if you
the cause of the fault has been eliminated,
you have verified that there is no danger to personnel or objects.
WARNING!
If you bypass, remove or override a safety device in any other way, you are endangering
yourself and other persons working on the lathe. The possible consequences are:
injuries due to components or workpieces flying off at high speed,
contact with rotating parts and
fatal electrocution,
pulling-in of clothes.

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WARNING!
The separating protective equipment which is made available and delivered together
with the machine is designed to reduce the risk of workpieces or fractions of them which
being expelled, but not to remove them completely.
Always work carefully and observe the limits of their machining process.
The lathe includes the following safety devices:
a lockable main switch,
an emergency stop switch,
a lathe chuck protection with position switch,
a mechanical spindle brake,
a protective cover on the headstock with position switch,
a recoil spring as protective cover on the lead screw, the coil spring prevents the pulling-in
of clothes into the lead screw.
an overload clutch on the feed rod,
safety screws for the Camlock bolts on the workpiece holder.
a chips shield.
1.9.1 Lockable main switch
In the "0" position, the lockable main
switch can be secured against accidental
or non-authorised switching on by means
of a padlock.
When the main switch is switched off, the
power supply to the machine is com-
pletely interrupted.
Img.1-1: Main switch
WARNING!
Dangerous voltage even if the main switch is switched off.
The areas marked by the pictogram might contain live parts, even if the main switch is
switched off.
Main switch

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1.9.2 Emergency stop button
CAUTION!
The drive or the lathe chuck will continue to run for a while, depending on the mass
moment of inertia of the lathe chuck and the workpiece. Use the spindle brake to slow
down the lathe more effectively.
The emergency stop button brings the
machine to a standstill.
Turn the knob to the right to unlock the
emergency stop mushroom switch.
CAUTION!
Only press the emergency stop button
in a genuine emergency. An
operational shut-down of the machine
must not be executed using the
emergency stop mushroom switch.
Img.1-2: EMERGENCY-STOP button
1.9.3 Protective cover with interlock switch
The headstock of the lathe is equipped
with a separating protective cover with
interlock switch. The protective cover can
only be opened when the main switch is
switched off.
The drive only starts when the protective
cover is closed.
Turn the main switch off, when the pro-
tective cover is to be opened for mainte-
nance or changing of gears.
Img.1-3: Protective cover of the headstock
EMERGENCY
Stop
button
Interlock switch

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1.9.4 Lathe chuck protection with position switch
The lathe is equipped with a lathe chuck
protection. The lathe can only be
switched on if the lathe chuck protection
is closed.
Img.1-4: Lathe chuck protection
1.9.5 Chip shield
Img.1-5: Chip shield
Polycarbonate windows
Polycarbonate viewing window in chip protection, must be visual inspected by the customer
responsible personnel at regular intervals to guarantee the operational safety of the machine.
Polycarbonate viewing panes are subject to an ageing process and are classified as wear
parts.
The aging of polycarbonate windows can not be detected by visual inspection. It is therefore
necessary to replace the polycarbonate windows after a certain time.
Prolonged exposure from polycarbonate windows to cutting fluids can lead to accelerated age-
ing, i.e. deterioration of the mechanical properties (brittleness). Coolant vapours, detergents,
greases and oils or other corrosive substances from the operator side can also lead to a deteri-
Lathe chuck pro-
tection
closed
Positions switch
Lathe chuck pro-
tection
open
Chip shield
Sight window
Setscrews

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oration of the polycarbonate windows. The result is a reduced retention capability of the poly-
carbonate viewing pane against chips and potentially flying parts.
1.9.6 Protective cover on the lead screw
Img.1-6: Protective cover of lead screw
1.9.7 Prohibition, warning and mandatory signs
INFORMATION
All warning and mandatory signs must be legible. They must be checked regularly.
1.10 Safety check
Check the lathe at least once per shift. Inform the person responsible immediately of any dam-
age, defects or changes in the operating function.
Check all safety devices
at the beginning of each shift (with the machine stopped),
once a week (with the machine in operation),
after all maintenance and repair work.
Check that prohibition, warning and information signs and the labels on the lathe
are legible (clean them, if necessary)
are complete.
INFORMATION
Organise the checks according to the following table;
Spiral spring as a protective cover
General check
Equipment Check OK
Guards Mounted, firmly bolted and not damaged
Signs,
Markers
Installed and legible
Date: Checked by (signature):

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1.11 Personnel protective equipment
For certain work personal protective equipment is required.
Protect your face and your eyes: Wear a safety helmet with facial protection when perform-
ing work where your face and eyes are exposed to hazards.
Wear protective gloves when handling pieces with sharp edges.
Wear safety shoes when you assemble, disassemble or transport heavy components.
Use ear protection if the noise level (emission) in the workplace exceeds 80 dB (A).
Before starting work make sure that the required personal protective equipment is available
at the work place.
CAUTION!
Dirty or contaminated personnel protective equipment can cause illness. It must be
cleaned after each use and at least once a week.
1.12 For your own safety during operation
We provide information about the specific dangers when working with and on the lathe in the
descriptions for these types of work.
WARNING!
Before activating the lathe ensure that this will neither endanger other persons nor
cause damage to equipment.
Avoid any unsafe work methods:
Avoid any unsafe work methods:
Make sure that your work does not endanger anyone.
Clamp the workpiece tightly before activating the lathe.
Observe the maximum lathe chuck opening.
Wear safety goggles.
Do not remove the turning chips by hand. Use a chip hook and / or a hand brush to remove
turning chips.
Clamp the turning tool at the correct height and with the least possible overhang.
Functional check
Equipment Check OK
EMERGENCY-STOP
mushroom switch
After activating the emergency stop mushroom button, the control voltage on
the lathe will shut off. The spindle continues to rotate for a while, depending on
the mass moment of inertia of the spindle and workpiece.
Positions switch
Lathe chuck protection
The spindle drive of the lathe must only be switch on if the lathe chuck
protection is closed.
Positions switch
Protective cover of the
headstock
The spindle drive of the lathe must only be switch on if the protective cover of
the headstock is closed.
Positions switch
Spindle brake
The lathe must be switched off if the mechanical spindle brake is activated.
Date: Checked by (signature):

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Turn off the lathe before measuring the workpiece.
The instructions described in these operating instructions must be strictly observed during
assembly, operation, maintenance and repair.
Do not work on the lathe if your concentration is reduced, for example, because you are
taking medication.
Observe the accident prevention regulations issued by your Employers Liability Insurance
Association or other supervisory authorities responsible for your company.
Inform the supervisor about all hazards or faults.
Stay at the lathe until all movements have come to a complete standstill.
Use the prescribed personnel protective equipment. Make sure to wear a well-fitting work
suit and, if necessary, a hairnet.
1.13 Safety during maintenance
Inform the operators in good time of any maintenance and repair works.
Report all safety-relevant changes and performance characteristics of the lathe. Any changes
must be documented, the operating instructions updated and machine operators instructed
accordingly.
1.13.1 Disconnecting and securing the lathe
Turn off the main switch of the lathe before starting any maintenance or repair work.
Use a padlock to prevent the switch from being turned on without authorization and keep the
key in a safe place.
All machine parts as well as all dangerous voltages are switched off.
Excepted are only the positions which are marked with the adjoining pictogram. These positions
may be live, even if the main switch is switched off.
Attach a warning sign to the lathe.
WARNING!
Live parts and moves of machine parts can injure you or others dangerously!
Proceed with extreme care if you cannot switch off
the lathe by turning off the main switch for necessary procedures (e.g. functional
control).
1.13.2 Using lifting equipment
WARNING!
The use of unstable lifting and load suspension equipment that might break under load
can cause severe injuries or even death.
Check to ensure that the lifting and load-suspension equipment are of sufficient load-
bearing capability and are in perfect condition.
Observe the accident prevention regulations issued by your Employers Liability
Insurance Association or other supervisory authorities applicable to your company.
Fasten the loads properly. Never walk under suspended loads!
1.13.3 Mechanical maintenance work
Remove or install protection safety devices before starting or after completing any mainte-
nance work; this include:
covers,
safety instructions and warning signs,
grounding cables.
If you remove protection or safety devices, refit them immediately after completing the work.

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Check that they are working properly!
1.14 Accident report
Inform your supervisors and Optimum Maschinen Germany GmbH immediately in the event of
accidents, possible sources of danger and any actions which almost led to an accident (near
misses).
There are many possible causes for "near misses".
The sooner they are notified, the quicker the causes can be eliminated.
INFORMATION
We provide information about the dangers of working with and on the lathe in these work
descriptions.
1.15 Electrical system
 Qualified electrician on page 12
Have the machine and/or the electric equipment checked regularly. Immediately eliminate all
defects such as loose connections, defective wires, etc.
A second person must be present during work on live components to disconnect the power in
the event of an emergency. Disconnect the lathe immediately if there is a malfunction in the
power supply!
Comply with the required inspection intervals in accordance with the factory safety directive,
operating equipment inspection.
The operator of the machine must ensure that the electrical systems and operating equipment
are inspected with regards to their proper condition, namely,
by a qualified electrician or under the supervision and direction of a qualified electrician,
prior to initial commissioning and after modifications or repairs, prior to recommissioning
and at certain intervals.
The deadlines must be set so that arising, foreseeable defects can be detected in a timely man-
ner.
The relevant electro-technical rules must be followed during the inspection.
The inspection prior to initial commissioning is not required if the operator receives confirma-
tion from the manufacturer or installer that the electrical systems and operating equipment com-
ply with the accident prevention regulations.
Permanently installed electrical systems and operating materials are considered constantly
monitored if they are continually serviced by qualified electricians and inspected by means of
measurements during operation (e.g. monitoring the insulation resistance).
1.16 Inspection deadlines
Define and document the inspection deadlines for the machine in accordance with § 3 of the
Factory Safety Act and perform an operational risk analysis in accordance with § 6 of the Work
Safety Act. Also use the inspection intervals in the maintenance section as reference values. 
Check up, inspection and maintenance on page 59.