Optimum OPTiturn TM 4010 User manual

GB
OPTIMUM
MASCHINEN - GERMANY
Operating Manual
Version 1.0.1
Lathe
Part no. 3403040
3403045

OPTIMUM
MASCHINEN - GERMANY
Version 1.0.1 dated 2018-01-31Page 2 Translation of the original instructions
TM4010 | TM4010DGB
Table of contents
1 Safety
1.1 Type 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 misuses...........................................................................................................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 ....................................................................12
1.7 Operator 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 mushroom switch .............................................................................................14
1.9.3 Protective cover with interlock switch..........................................................................................14
1.9.4 Lathe chuck protection with position switch ................................................................................14
1.9.5 Chip guard shield ........................................................................................................................15
1.9.6 Prohibition, warning and mandatory signs ..................................................................................15
1.10 Safety check ...........................................................................................................................................15
1.11 Personnel protective equipment .............................................................................................................16
1.12 For your own safety during operation .....................................................................................................16
1.13 Safety during maintenance.....................................................................................................................17
1.13.1 Disconnecting and securing the lathe .........................................................................................17
1.13.2 Using lifting equipment ................................................................................................................17
1.13.3 Mechanical maintenance work ....................................................................................................17
1.14 Accident report........................................................................................................................................18
1.15 Electronics ..............................................................................................................................................18
1.16 Inspection deadlines...............................................................................................................................18
2 Technical specification
2.1 Electrical connection...............................................................................................................................20
2.2 Drive motor power ..................................................................................................................................20
2.3 Headstock...............................................................................................................................................20
2.4 Feeds and pitches ..................................................................................................................................20
2.5 Slides......................................................................................................................................................20
2.6 Tailstock..................................................................................................................................................20
2.7 Steady and follow rest ............................................................................................................................20
2.12 Emissions ...............................................................................................................................................21
2.8 Coolant system .......................................................................................................................................21
2.9 Work area, weights .................................................................................................................................21
2.10 Environmental conditions........................................................................................................................21
2.11 Operating material ..................................................................................................................................21
2.13 Dimensions, installation plan ..................................................................................................................23
3 Delivery, interdepartmental transport, unpacking
3.1 Unpacking the machine ..........................................................................................................................24
3.2 Scope of delivery ....................................................................................................................................24
3.3 Transport ................................................................................................................................................24

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MASCHINEN - GERMANY
Version 1.0.1 dated 2018-01-31 Page 3Translation of the original instructions
TM4010 | TM4010D GB
3.3.1 Load suspension point ................................................................................................................ 25
3.3.2 Gravity of the machine ................................................................................................................ 25
3.3.3 Lifting with a forklift...................................................................................................................... 25
3.3.4 Lifting by crane............................................................................................................................ 26
3.4 Installation and assembly ....................................................................................................................... 26
3.4.1 Installation site requirements ...................................................................................................... 26
3.5 Cleaning the machine............................................................................................................................. 27
3.5.1 Lubrication................................................................................................................................... 27
3.6 Anchor-free assembly ............................................................................................................................ 28
3.6.1 Dimension of vibration damper ................................................................................................... 28
3.6.2 Anchored assembly..................................................................................................................... 28
3.6.3 Aligning of the machine............................................................................................................... 30
3.7 Fill with coolant....................................................................................................................................... 31
3.8 First commissioning................................................................................................................................ 31
3.9 Electric three-phase connection............................................................................................................. 31
3.10 Warming up the machine ....................................................................................................................... 32
3.11 Functional check .................................................................................................................................... 32
4Operation
4.1 Control and indicating elements ............................................................................................................. 33
4.2 Safety ..................................................................................................................................................... 34
4.2.1 Control elements......................................................................................................................... 34
4.3 Switching on the machine ...................................................................................................................... 35
4.4 Switching the machine off ...................................................................................................................... 35
4.5 Resetting an emergency stop condition ................................................................................................. 35
4.6 Power failure, Restoring readiness for operation ................................................................................... 35
4.7 Momentary switch, direct run ................................................................................................................. 35
4.8 Speed setting ......................................................................................................................................... 35
4.9 Turning direction..................................................................................................................................... 35
4.10 Feed ....................................................................................................................................................... 36
4.10.1 Feed speed ................................................................................................................................. 36
4.11 Tables for thread cutting......................................................................................................................... 36
4.11.1 Metric thread cutting table........................................................................................................... 36
4.11.2 Exchange, change of position of the change gears .................................................................... 37
4.11.3 Inch thread cutting table.............................................................................................................. 38
4.12 Tool holder ............................................................................................................................................. 39
4.13 Lathe spindle fixture ............................................................................................................................... 40
4.13.1 Fasten workpiece holder............................................................................................................. 40
4.13.2 Lathe chuck................................................................................................................................. 41
4.13.3 Speed information, maintenance recommendations, reference speed in accordance with DIN 6386
41
4.13.4 Influencing factors that significantly impact the tensioning force ................................................ 42
4.13.5 Lathe chuck maintenance ........................................................................................................... 43
4.13.6 Clamping long workpieces .......................................................................................................... 43
4.13.7 Mounting workpiece holder ......................................................................................................... 44
4.14 Tailstock ................................................................................................................................................. 44
4.14.1 Cross-adjustment of the tailstock................................................................................................ 44
4.15 General operating instructions ............................................................................................................... 45
4.15.1 Longitudinal turning..................................................................................................................... 45
4.15.2 Face turning and recessing......................................................................................................... 45
4.15.3 Fixing the lathe saddle ................................................................................................................ 45
4.15.4 Turning between centres............................................................................................................. 46
4.15.5 Turning short tapers with the top slide ........................................................................................ 46
4.15.6 Thread cutting ............................................................................................................................. 47
4.16 Coolant equipment ................................................................................................................................. 48
4.16.1 Cooling lubricants........................................................................................................................ 48

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Version 1.0.1 dated 2018-01-31Page 4 Translation of the original instructions
TM4010 | TM4010DGB
4.17 Lathe chuck K11-200/D5 ........................................................................................................................49
4.17.1 Basic safety instructions..............................................................................................................49
4.17.2 Calculating the required clamping force for a given speed .........................................................50
4.17.3 Clamping force-speed diagram - Lathe chuck K11-200/D5 ........................................................51
4.17.4 Clamping jaw centrifugal force ....................................................................................................51
4.17.5 Technical data of lathe chuck......................................................................................................54
4.17.6 Lubricating and cleaning the lathe chuck ....................................................................................54
5 Cutting speeds
5.1 Selecting the cutting speed.....................................................................................................................55
5.2 Influences on the cutting speed..............................................................................................................55
5.3 Example for the determination of the required speed on your lathe .......................................................55
5.4 Table cutting speeds...............................................................................................................................56
6 Maintenance
6.1 Safety......................................................................................................................................................57
6.1.1 Preparation..................................................................................................................................57
6.1.2 Restarting ....................................................................................................................................57
6.1.3 Cleaning ......................................................................................................................................58
6.2 Check up, inspection and maintenance..................................................................................................58
6.3 Lubricating and cleaning the lathe chuck................................................................................................64
6.4 Repair .....................................................................................................................................................64
6.4.1 Customer service technician .......................................................................................................64
6.5 Cooling lubricants and tanks...................................................................................................................65
6.5.1 Inspection plan for water-mixed cooling lubricants......................................................................66
7 Ersatzteile - Spare parts - TM4010 - TM4010D
7.1 Ersatzteilbestellung - Ordering spare parts ............................................................................................67
7.2 Elektrische Ersatzteile - Electrical spare parts........................................................................................67
7.3 Schaltplan - Wiring diagram....................................................................................................................67
7.4 Maschinenbett - Machine bed.................................................................................................................68
7.5 Antrieb, Steuerung - Actuation, control...................................................................................................70
7.6 Getriebe Spindelstock 1-6 - Headstock gear 1-6....................................................................................72
7.7 Getriebe Spindelstock 2-6 - Headstock gear 2-6....................................................................................73
7.8 Getriebe Spindelstock 3-6 - Headstock gear 3-6....................................................................................74
7.9 Getriebe Spindelstock 4-6 - Headstock gear 4-6....................................................................................75
7.10 Getriebe Spindelstock 5-6 - Headstock gear 5-6....................................................................................76
7.11 Getriebe Spindelstock 6-6 - Headstock gear 6-6....................................................................................77
7.12 Vorschubgetriebe 1-6 - Feed gear 1-6...................................................................................................80
7.13 Vorschubgetriebe 2-6 - Feed gear 2-6...................................................................................................80
7.14 Vorschubgetriebe 3-6 - Feed gear 3-6...................................................................................................81
7.15 Vorschubgetriebe 4-6 - Feed gear 4-6...................................................................................................82
7.16 Vorschubgetriebe 5-6 - Feed gear 5-6...................................................................................................83
7.17 Vorschubgetriebe 6-6 - Feed gear 6-6...................................................................................................84
7.18 Wechselradgetriebe - Change gear........................................................................................................87
7.19 Schlosskasten 1-3 - Apron 1-3 ...............................................................................................................88
7.20 Schlosskasten 2-3 - Apron 2-3 ...............................................................................................................89
7.21 Schlosskasten 3-3 - Apron 3-3 ...............................................................................................................90
7.22 Planschlitten - Cross slide ......................................................................................................................93
7.23 Oberschlitten - Top slide.........................................................................................................................94
7.24 Reitstock - Tailstock................................................................................................................................97
7.25 Feststehehde Lünette - Steady rest........................................................................................................99
7.26 Mitlaufende Lünette - Follow rest..........................................................................................................101
7.27 Drehfutterschutz - Chuck protection .....................................................................................................102
7.28 Späneschutz - Chip protection..............................................................................................................103
7.29 TM 4010D - Wegmeßsystem - Path measurement system..................................................................104
7.30 Schaltplan - Wiring diagram 1 - 3 .........................................................................................................105

OPTIMUM
MASCHINEN - GERMANY
Version 1.0.1 dated 2018-01-31 Page 5Translation of the original instructions
TM4010 | TM4010D GB
7.31 Schaltplan - Wiring diagram 2 - 3 ......................................................................................................... 106
7.32 Schaltplan - Wiring diagram 3 - 3 ......................................................................................................... 107
8 Malfunctions
9 Appendix
9.1 Copyright .............................................................................................................................................. 112
9.2 Terminology/Glossary .......................................................................................................................... 112
9.3 Change information manual ................................................................................................................. 112
9.4 Liability claims/warranty ....................................................................................................................... 113
9.5 Storage................................................................................................................................................. 114
9.6 Dismantling, disassembling, packing and loading................................................................................ 114
9.6.1 Decommissioning...................................................................................................................... 115
9.6.2 Dismantling ............................................................................................................................... 115
9.6.3 Disassembly.............................................................................................................................. 115
9.6.4 Packing and loading.................................................................................................................. 115
9.7 Disposal of new device packaging ....................................................................................................... 115
9.8 Disposal of lubricants and cooling lubricants ....................................................................................... 115
9.9 Disposal via municipal collection facilities ............................................................................................ 116
9.10 Product follow-up.................................................................................................................................. 116

OPTIMUM
MASCHINEN - GERMANY
Version 1.0.1 dated 2018-01-31Page 6 Translation of the original instructions
TM4010 | TM4010DGB
TM4010_TM4010D_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 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, Germany
Email: [email protected]

OPTIMUM
MASCHINEN - GERMANY
Version 1.0.1 dated 2018-01-31 Page 7Translation of the original instructions
TM4010 | TM4010D GB
TM4010_TM4010D_GB_1.fm
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 Type plates
Machine variants:
TM 4010 - without digital path display
TM 4010D - with digital path display
provides further instructions
calls on you to act
listings
Master Labels
Optimum Maschinen
Germany GmbH
Dr.-Robert-Pfleger-Str. 26
D-96103 Hallstadt
2.000 U/min
20
SN
Year
500 kg
2,2 kW
400 V 3 Ph
~50 Hz
TM 4010D
NO.
DE
EN
FR
ES
IT
CS
DA
EL
FI
HU
NL
PL
PT
RO
RU
SK
SL
SV
TR
Drehmaschine
Lathe
Tour
Torno
Tornio
Soustruh
Drehbænk
Tόρνος
Kärkisorvi
Esztergapad
Draaibank
Tokarka
Torno
Strung
Токарный станок
Sústruh
Stružnica
Bänksvarv
Torna Tezgahı
3403045
Optimum Maschinen
Germany GmbH
Dr.-Robert-Pfleger-Str. 26
D-96103 Hallstadt
2.000 U/min
20
SN
Year
500 kg
2,2 kW
400 V 3 Ph
~50 Hz
TM 4010
NO.
DE
EN
FR
ES
IT
CS
DA
EL
FI
HU
NL
PL
PT
RO
RU
SK
SL
SV
TR
Drehmaschine
Lathe
Tour
Torno
Tornio
Soustruh
Drehbænk
Tόρνος
Kärkisorvi
Esztergapad
Draaibank
Tokarka
Torno
Strung
Токарный станок
Sústruh
Stružnica
Bänksvarv
Torna Tezgahı
Master Labels
3403040

OPTIMUM
MASCHINEN - GERMANY
Version 1.0.1 dated 2018-01-31Page 8 Translation of the original instructions
TM4010 | TM4010DGB
TM4010_TM4010D_GB_1.fm
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 slip-
ping!
Warning: risk of stumbling! Warning: hot surface!
Warning: biological hazard!

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Version 1.0.1 dated 2018-01-31 Page 9Translation of the original instructions
TM4010 | TM4010D GB
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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 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
Warning: automatic start-
up!
Warning: tilting danger! Warning: suspended loads! Caution, danger of explo-
sive substances!
Switching on forbidden! Do not climb onto the
machine!
Do not clean with com-
pressed air!
Read the operating instruc-
tions before commission-
ing!
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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Version 1.0.1 dated 2018-01-31Page 10 Translation of the original instructions
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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!
Extremely severe injuries due to non-intended use.
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.
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.
When working do not generate any continuous chips. Adjust the cutting speed when contin-
uous chips are produced. 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 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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MASCHINEN - GERMANY
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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 operator must also
check the personnel‘s knowledge level,
document the training/instruction,
have attendance at the training/instruction confirmed by signature and
check whether personnel is working in a manner that shows awareness of safety and risks.
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 manual,
be familiar with all safety devices and regulations,
be able to operate the lathe.
1.6.5 Additional requirements regarding the qualification
Additional requirements apply for work on electrical components or equipment:

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MASCHINEN - GERMANY
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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 Operator 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 are 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.
Extra precautionary measures must be taken before machining flammable materials (e.g.
aluminium, magnesium) or using combustible agents (e.g. spirit) to avert a health
hazard.
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!
Although the isolating safety devices provided and delivered with the machine are
designed to reduce the risks of workpieces being ejected or parts of tools or workpieces
breaking off, they cannot eliminate these risks completely.
Always work carefully and observe the limits of their machining process.
The lathe includes the following safety devices:
a lockable main switch,
two emergency-stop switch,
a lathe chuck protection with position switch,
an electromagnetic spindle brake in the drive motor,
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-author-
ised switching on by means of a padlock.
When the main switch is switched off, the power supply to the machine is completely inter-
rupted.
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.
1.9.2 Emergency-stop mushroom switch
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.
The emergency stop button brings the machine to a standstill.
Turn the knob to the right to unlock and release the emergency stop button.
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.
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 of machine is switched off.
The drive only starts when the protective cover is closed.
Turn the main switch off, when the protective cover is to be opened for maintenance or chang-
ing of gears.
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.

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1.9.5 Chip guard 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-
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 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;
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.
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.
Functional check
Equipment Check OK
Emergency-stop push
button
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 may switch on only when 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.
Date: Checked by (signature):

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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 applicable to 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 caution if you
the lathe by turning off the main switch due to required works (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.
Check that they are working properly!

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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 Electronics
 "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. If there is a fault in the power supply, switch off the lathe immedi-
ately!
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 set intervals.
The intervals must be set so that foreseeable defects can be detected in a timely manner, when
they occur.
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 58.

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2 Technical specification
The following information represents the dimensions and indications of weight and the manu-
facturer‘s approved machine data.
TH4010 TH4010D
2.1 Electrical connection
3 x 400V ~ 50 Hz 3 kW
2.2 Drive motor power
Rated operation type S6 - 60%
Driving power 2.2 kW
Height of centres [ mm ] 200
Distance between centres [ mm ] 1000
Swing diameter over machine bed [ mm ] 400
Swing diameter over cross slide [ mm ] 250
Main spindle bore [ mm ] 52
2.3 Headstock
Main spindle nose DIN ISO 702-2 no. 5 - Camlock
Reducing cone in the main spindle MT4
Main spindle morse taper MT6
Spindle speeds [ rpm ] 2000 | 1255 | 755 | 460 | 300 | 190 | 155 | 70
Gear levels 8
2.4 Feeds and pitches
Longitudinal feed [ mm/rev ] 0.014 to 0.38mm
Cross feed [mm/rev] 0.052 to 1.392mm
Metric thread [ mm / rev ] 0.4 to 7mm
Inch threads [ threads / inch ] 56 - 4
2.5 Slides
Travel cross slide [mm] 185
Travel top slide [mm] 98
maximum dimension for lathe tool in
quadruplicate tool holder [mm] 30
2.6 Tailstock
Quill diameter [mm] 50
Quill travel [mm] 110
2.7 Steady and follow rest
Steady rest passage min. - max. [mm] 7 - 102
Follow rest passage min. - max. [mm] 10 - 60