Precision matthews PM-1440BV User manual

1PM-1440BV v3 2020-10 Copyright © 2020 Quality Machine Tools, LLC
Model PM-1440BV Lathe
Heavy duty VFD gap-bed machine
Continuously variable spindle speed from 40 to 400 & 220 to 1800 rpm
Large bore spindle: 2 inch clearance
D1-5 camlock spindle mount
40 in. between centers, 14 in. swing over bed, 18-3/4 in. over gap
Multi-speed gearbox for full-range screw cutting, TPI & mm pitch
Bidirectional power feed for saddle & cross-slide
Weight, including cast iron stand 1800 lb
PM-1440BV Includes foot brake, coolant system & work light.
Options shown here: 2-axis DRO and quick-change toolpost
(wedge-type).

2PM-1440BV v3 2020-10 Copyright © 2020 Quality Machine Tools, LLC
PM-1440BV
FAQ
No tachometer display?
No fans running?
Check main switch ON
Check circuit breaker QF1
AC power connected,
but nothing runs
This manual contains essential safety advice on the proper setup, operation, maintenance, and service of
the PM-1440BV lathe. Failure to read, understand and follow the manual may result in property damage
or serious personal injury.
There are many alternative ways to install and use a lathe. As the owner of the lathe you are solely
responsible for its proper installation and safe use. Consider the material contained in this manual to
be advisory only. Quality Machine Tools, LLC cannot be held liable for injury or property damage during
installation or use, or from negligence, improper training, machine modications or misuse.
This manual describes PM-1440BV machines as shipped from April 2017. There may be detail di󰀨erences between your
specic machine and the information given here (with little or no impact on functionality). Please email us if you have
questions about any aspect of the manual or your machine (see our website www.precisionmatthews.com for support
addresses). Your feedback is welcomed!
The motor didn’t run when
power was connected
This indicates an error
condition in the drive unit
(VFD).
Un-jam spindle/saddle/
cross slide, then press
RESET button
RESET light ON
By design it should NOT run if the
Motor Control lever is UP or DOWN
when power is connected.
Electrical schematic, Section 5: Move
the Motor Control switch to neutral
= OFF (mid travel), to energize the
gate relay KA0, thus restoring normal
conditions.
Copyright © 2020 Quality Machine Tools, LLC
This material was originated by Precision Matthews. No portion of
the manual may be reproduced or distributed in any form without
the written approval of Quality Machine Tools, LLC.
The 3 gearboxes in this machine (Headstock,
Saddle Feed and Apron) may have been
shipped empty. They must be lled before
use, see Section 4.
Motor doesn’t
run at all
Footbrake moves freely?
Treadle should be fully UP
for the motor to run.
E-Stop button in? Rotate it,
should pop out.

3PM-1440BV v3 2020-10 Copyright © 2020 Quality Machine Tools, LLC
Section 1 INSTALLATION
THESE ARE THE MAIN POINTS TO WATCH OUT FOR!
But read the following pages for more information
• Handling the lathe is at least a two-man job.
• Lifting gear – sling, hoist or forklift – must be rated for at least 1-1/2 tons.
• Working location of the lathe must allow space for removal of the belt cover at left; also,
access to the coolant system (back of right hand cabinet) and the electrical box at the
back of the headstock.
• Power requirement is 220V, 60Hz, single phase.
• Extension cord not recommended; if no alternative, use 12 AWG not longer than 20 ft.
• Before connecting power be sure that:
1. The machine is on a rm footing.
2. Chuck camlocks tight, no wrench left in chuck.
3. Saddle and cross slide approx. mid-travel, power feed disengaged (Figure 1-8).
4. The speed control knob is set for a low spindle speed (counter clockwise), with the
headstock gear shift lever set to L.
SETTING UP THE LATHE
The PM-1440BV is shipped fully assembled in a single pack-
ing case. The machine can be lifted in one piece by an over-
head hoist or forklift with slings and/or chains, all items rated
for a total weight of at least 1-1/2 tons. A suggested setup for
lifting is shown in Figure 1-1.
When selecting a location for the lathe, allow su󰀩cient room at
the right to allow removal/servicing of the leadscrew, feed shaft
and motor control shaft.
Be sure to keep all lifting gear clear of any part of the
lathe, especially the 3 shafts at the front. Use at least 2-by
spreaders.
Figure 1-1 Lifting with slings
Spreader under the bed
keeps slings/chains clear
of feed shafts, etc.
Before lifting, remove the chuck, if installed, then move the
tailstock and saddle as far to the right as possible to balance
the machine at the point(s) of suspension, Figure 1-1.
Check oil levels in all gearboxes before use
With the lathe in its permanent location, level it using metal
shims under the cabinets, or (preferred), install six 500 lb-rated
leveling mounts in the mounting holes of the two stand cabi-
nets, 4 for the left hand cabinet, 2 for the right. The special
mounts shown in Figure 1-2, available from Precision Mat-
thews, allow leveling adjustment from above. To install this
type of mount, remove the threaded stem from the inverted
cup stamping (yellow), then place the cup under the stand with
holes aligned — no washer between stand and mount. If there
is insu󰀩cient headroom in the stand, shorten the threaded
stem, then re-install it through the hole in the stand. Once the
stem has bottomed in the mount, further rotation of the stem
(using a wrench) expands the inner core of the mount, thus
raising its upper surface. Secure with the locknut.
Figure 1-2 Top-adjusting leveling mount (optional)
LEVELING
The following procedure ensures that the lathe bed is in the
same state as it was when the lathe was checked for accuracy
in manufacture — level from end to end along the bed, and
from front to back. In other words, no warping.
Make sure all leveling mounts and/or shims are properly
weight bearing, rmly in contact with the oor. Check and ad-
just level from end to end using a precision machinist’s level, if

4PM-1440BV v3 2020-10 Copyright © 2020 Quality Machine Tools, LLC
COOLANT TANK
Inspect the coolant tank and pump assembly in the RH cabi-
net, Figure 1-4. The tank may have become dislodged in ship-
ment. Level it if necessary. Check that the footbrake spindle is
not pressing on the side of the tank. Reposition the spindle if
necessary.
Figure 1-3 Chip tray
Figure 1-4 Coolant tank
CLEANUP
Metal surfaces may have been protected by thick grease and/
or paper. Carefully remove these using a plastic paint scraper,
disposable rags and a light-oil such as WD-40.
available. If not, use the most reliable level on hand. Check and
adjust level front-to-back across the bed using a matched pair
of spacer blocks to clear the Vee tenons on the bed ways. The
blocks need to be at least 1/4 inch thick, ground or otherwise
accurately dimensioned. Alternatively, check for level on the
ground surface of the cross slide as the carriage is traversed
from end to end. See also "Aligning the Lathe" in Section 4.
FOOTBRAKE INTERLOCK
The lathe will not run if the footbrake switch fails to close when
the foot treadle is released (brake OFF). This switch is locat-
ed inside the LH stand cabinet. Check that the D-shape cam
operates the switch when the treadle is pressed, Figure 1-5.
CHIP TRAY
Check that the chip tray, Figure 1-3, can be pulled forward
without snagging coolant hoses and worklight wiring. Use ca-
ble ties if necessary.
Figure 1-5 Footbrake switch
ELECTRICAL CONNECTIONS
As shipped, the PM-1440BV is set for 220 Vac single phase
power.
Read Initial Checks, below, before connecting power
Remove the upper rear cover from the LH cabinet. If the lathe
did not come with a pre-installed power cord, connect the pow-
er source through a strain relief bushing to the port shown in
Figure 1-6 using 12 AWG (minimum) 3-wire cord. The 220V
input is identied as L, N at left of the connector strip.
Figure 1-6 Connections to upper electrical box

5PM-1440BV v3 2020-10 Copyright © 2020 Quality Machine Tools, LLC
INITIAL CHECKS
Read Section 3 if unsure about any item in this list
Do not change speed while the motor is running
BEFORE connecting power, do the following:
1. Visually check the entire machine for possible distur-
bance in shipping, including the motor, Vee belts and
external gears under the belt cover left of the headstock.
Replace the belt cover.
2. Check oil level (sight glasses) in the headstock, the
saddle feed gearbox, and the apron. See Section 4.
3. If a chuck or faceplate is installed, check tightness of the
six Camlocks on the spindle nose, Section 3.
4. Set the speed gear lever to L (low). Make sure the gears
are properly meshed by “jiggling while shifting” — ro-
tate the chuck back and forth by hand while moving the
levers into position. Make certain that the motor control
lever is set to OFF, mid-travel, Figure 1-7.
5. Set the speed control knob fully counter clockwise (slow-
est speed).
6. Set the Feed Direction knob to its center (neutral)
position, Figure 1-8.
7. Check that there are no clamps or locks on moving parts.
8. Check that the footbrake treadle is released (UP).
9. Set the saddle and cross slide to approximate mid-travel.
10. Connect and switch on 220 Vac power (switch located
at back of headstock). The tachometer display (spindle
speed), Figure 1-8, should light, unless a circuit breaker
in the electrical box has tripped.
11. Be sure the Emergency Stop (E-Stop) button has not
been pushed in (it should pop out when twisted clock-
wise).
12. Shift the motor control lever DOWN. Turn the speed
control knob a few degrees clockwise to run the motor
at low speed. The spindle should turn Forward, counter
clockwise, viewed at the chuck (nose) end. The control
system can be rewired for DOWN = Reverse, see below.
13. Check the emergency function by pressing the E-Stop
button. The motor should stop. If this doesn’t happen,
the E-stop function is defective, and needs attention.
14. Reset (twist) the E-Stop button to restore power.
15. Check that the footbrake stops the motor.
16. Return the motor control lever to OFF, mid-travel.
17. Shift the motor control lever UP. The spindle should
Reverse, clockwise rotation, viewed at the chuck (nose)
end. The control system can be rewired for UP = Forward, see
below.
Figure 1-7 Motor control lever
REVERSING THE MOTOR CONTROL LEVER
See electrical box photo, page 27
Figure 1-8 Front panel
controls
(1) Speed range selector
(2) Speed adjust knob
(3) Tachometer display
(4) Feed direction lever,
shown here in neutral
(5) JOG push button, runs
the spindle forward a few
degrees when pressed
(or backward if the motor
control lever has been
re-directed)
(6) Feed gearbox control,
one of four; only the feed
shaft is driven (not the
leadscrew) when this knob
is set to 0
(7) E-Stop button. Disables
the machine when pressed;
twist (pops out) to restore
power
(8) Coolant ON/OFF
OPTIONAL TEST RUN PROCEDURE
Run the spindle for a few minutes, forward and reverse, at
various speeds.
If desired, the saddle feed gearbox may also be run at this
time, but rst make certain that all components a󰀨ected have
been lubricated, then exercise the saddle and cross slide man-
ually before power-feeding — see Section 3 for power feed
directions.
Precision Matthews recommends draining and relling all
three gearboxes (Headstock, Saddle Feed and Apron) af-
ter approximately 20 hours of initial run time. Lubricants
are specied in Section 4.
ALIGNING THE LATHE
The most important attribute of a properly set up lathe is its
ability to “machine parallel”, to cut a cylinder of uniform diame-
ter over its entire length. In other words, no taper.
Leveling of the lathe is a part of this, see earlier in this section.
Equally important is the alignment of the center-to-center axis
with the lathe bed, as seen from above. [Vertical alignment is
nowhere near as critical, rarely causing taper unless the lathe
is damaged or badly worn.] For more information see the nal
pages of Section 4, Servicing the Lathe.

6PM-1440BV v3 2020-10 Copyright © 2020 Quality Machine Tools, LLC
Section 2 FEATURES & SPECIFICATIONS
MODEL PM-1440BV Lathe
PM-1440BV Floor plan: approximate dimensions (not to scale)
General information
The PM-1440BV is a robust, heavy duty gap-bed lathe designed for day-in, day-out use in production and in the
larger model shop. It features a 2 HP motor with variable frequency single-phase/three-phase converter (VFD)
giving smoothly variable spindle speeds from 40 to 400 rpm and 220 to 1800 rpm. Power requirement is 220 Vac
1Ø.The lathe ships fully assembled, with foot brake, on cast iron stands (all-up weight 1800 lb).
The spindle has a 2-inch bore, and is unusually short — just 16-1/2 inches, ideal for through-spindle work such as
gunsmithing. Long service life is assured by high precision taper-roller spindle bearings, together with hardened
and ground bed ways, shafts and headstock gears. All gears in the machine are oil-bath lubricated.
A saddle-feed gearbox, together with a set of external change gears, provides for a full range of UNC and UNF
threads from 4 to 56 TPI, and metric threads from 0.4 to 7 mm pitch.
In addition to the leadscrew for thread-cutting operations the saddle-feed gearbox drives an independent feed shaft
that powers both the saddle and cross-slide. A friction clutch allows the saddle to be stopped precisely at any point
along the bed. The VFD comes with an electrical braking system, triggered by the footbrake, that stops the spindle
almost instantly, even at the highest speeds. A circulating coolant system is installed in the right hand stand cabinet.

7PM-1440BV v3 2020-10 Copyright © 2020 Quality Machine Tools, LLC
Dimensions, approximate overall, incl. stand
Width 71-1/2 in. x Height 51 in. x Depth 31 in. (full range
cross slide motion)
Footprint: 71-1/2 in. wide x 24 in. deep
Bed length, excluding headstock: 54 in.
Spindle centerline to oor: 46 in.
Weight, approximate:1800 lb net
Power requirement 220 Vac, 60 Hz, 1Ø, 12A max
Motor 2 HP, 3Ø (1Ø to 3Ø conversion in VFD)
Work envelope
Headstock center to tailstock center 40 in. max
Swing over bed 14 in. diameter
Swing over cross slide 8.81 in. diameter
Swing over gap 18.74 in. diameter
Gap insert length 8-3/16 in.
Spindle face to tailstock quill face 43-1/4 in. max
Saddle travel along bed 38-1/2 in.
Cross-slide travel 6-1/4 in.
Compound (top slide) travel 3-3/4 in.
Drive system
VFD drive with 2-speed gearbox)
Low range, rpm 40 to 400
High range, rpm 220 to 1800
Carriage drive, thread cutting Leadscrew 8 tpi
Inch threads Choice of 34, from 4 to 56 TPI
Metric threads Choice of 26, from 0.4 mm to 7 mm pitch
Saddle drive, turning operations Choice of feed rates from 0.002 to 0.0548 in./spindle rev
Cross slide drive, facing operations Choice of feed rates from 0.0007 to 0.0187 in./spindle rev
Spindle
Chuck/faceplate attachment D1-5 Camlock
Internal taper MT6
Spindle bore 2 in. diameter
Spindle length, LH end to chuck mounting face 16-1/2 in. overall
Spindle length, LH end to chuck face (typical) 19-1/4 in. approx.
Tailstock
Internal taper MT4
Quill travel 4 in.
Work holding (typical)
3-jaw chuck, 8 in.
4-jaw chuck, 8 in.
Faceplate
Center rest (steady rest) capacity Up to 3 in. diameter
Follower rest capacity Up to 1 in. diameter
PM-1440BV SPECIFICATIONS

8PM-1440BV v3 2020-10 Copyright © 2020 Quality Machine Tools, LLC
Everyday precautions
• This machine is intended for use by experienced users familiar with met-
al-working hazards.
• Untrained or unsupervised operators risk serious injury.
• Wear ANSI-approved full-face or eye protection at all times when using the
machine (everyday eyeglasses are not reliable protection against ying parti-
cles).
• Wear proper apparel and non-slip footwear – be sure to prevent hair, cloth-
ing or jewelry from becoming entangled in moving parts. Gloves – including
tight-tting disposables – can be hazardous!
• Be sure the work area is properly lit.
• Never leave chuck keys, wrenches or other loose tools on the machine.
• Be sure the workpiece, toolholder(s) and machine ways are secure before
commencing operations.
• Use moderation: light cuts, low spindle speeds and slow table motion give
better, safer results than “hogging”.
• Don’t try to stop a moving spindle by hand – allow it to stop on its own.
• Disconnect 220 Vac power from the lathe before maintenance operations
such as oiling or adjustments.
• Maintain the machine with care – check lubrication and adjustments daily
before use.
• Clean the machine routinely – remove chips by brush or vacuum, not com-
pressed air (which can force debris into the ways).
No list of precautions can cover everything.
You cannot be too careful!

9PM-1440BV v3 2020-10 Copyright © 2020 Quality Machine Tools, LLC
Section 3 USING THE LATHE
What is not in this section ...
The PM-1440BV is a conventional engine lathe that requires
little explanation except for details specic to this particular
model — speed selection, thread cutting, and the saddle/
cross-slide power feed system. Because the user is assumed
to be familiar with general purpose metal lathes, this section
contains very little tutorial.
Figure 3-1 Control panel & feed gearbox
(1) Speed range selector; (2) Speed adjust knob; (3) Tachometer
(speed in rpm); (4) Saddle Feed direction selector — shown here in
neutral, no feed; (5) Jog push-button; (6) When set to 0as shown,
this knob selects feed shaft drive, disengaging the leadscrew; (7)
Emergency E-Stop button — must be OUT for the lathe to function.
Before doing ANYTHING, check the instal-
lation instructions and power-up procedure
in Section 1
STOP the motor before changing speed
RANGE, H to L, L to H
STOP the motor before changing feed DI-
RECTION and saddle feed GEARBOX selec-
tions
Don't use JOG unless the gears are fully
meshed
Before switching power on (switch at back of headstock), be
sure the E-Stop button is not pushed in, (7) Figure 3-1, and
that the Motor Control Lever on the apron is mid-travel, o󰀨,
Figure 3-2. Check that the drive train, L or H range, is properly
engaged, then operate the Motor Control Lever to run the spin-
dle in the desired direction. Adjust knob (2) to control spindle
speed.
Figure 3-2 Motor control lever
Mid-travel OFF, Down FORWARD, Up REVERSE
When changing ANY gear selection — speed range, feed direc-
tion, feed speed — rst stop the motor. Be patient! It is not always
possible to go directly from one mesh to another, so move the
spindle back and forth by hand while easing the lever/knob into
position. Don’t use JOG to do this! This may damage gears.
SADDLE FEED DIRECTION
The lever below the tachometer determines whether the sad-
dle feed is right to left — the usual direction for turning and
thread cutting — or reversed. The selected direction applies
to both the leadscrew and the saddle/cross slide power feed.
Power feed is OFF when the knob is at 12 o'clock position, as
in the photo.
JOG FEATURE
"Jog" is momentary-type push-button, active only if the Motor
Control lever is in the mid-travel (OFF) position, Figure 3-2.
Press the button briey to "nudge" the spindle forward by a
few degrees. Jog can be used to reposition the chuck and/or
workpiece, especially useful when low spindle-speed gearing
makes hand rotation di󰀩cult.
The control system can be rewired for "Reverse Jog", see
INITIAL CHECKS, Section 1.

10PM-1440BV v3 2020-10 Copyright © 2020 Quality Machine Tools, LLC
T S R U T S R U
A D 0.0187 0.0175 0.0140 0.0112 0.0094 0.0087 0.0070 0.0056
B D 0.0094 0.0087 0.0070 0.0056 0.0047 0.0044 0.0035 0.0028
A C 0.0047 0.0044 0.0035 0.0028 0.0024 0.0022 0.0017 0.0014
B C 0.0024 0.0022 0.0017 0.0014 0.0012 0.0011 0.0009 0.0007
ENGAGING THE POWER FEED
(For normal turning and facing operations)
To activate the feed shaft: 1. Set the Saddle Feed direction
lever, Figure 3-1 (4), to the left, and; (2) Set the upper right
knob on the gearbox to 0 (selections 1-2-3-4 are used only for
thread cutting with the leadscrew).
The power feed lever on the apron, Figure 3-4, is active only
when the feed shaft is rotating (the split-nut lever engages
the leadscrew).
When engaging power feed, move the lever gently, feeling
for the gears to mesh as you go. If the gears don’t engage at
the rst try, use the appropriate handwheel to jog the saddle
or cross slide, whichever one you wish to move under power.
The rate of power feed relative to spindle speed is set by se-
lector knobs on the gearbox, together with external change
gears on the end face of the headstock, Figure 3-3. Two pair-
ings are commonly used: 60T upper/60T lower, and 30T up-
per/60T lower. Feed rates are listed in Figure 3-5.
Figure 3-5 Power feed rates (inches per spindle rev)
For any given change gear and gearbox selection, sad-
dle motion is approximately 3 times cross-slide motion.
T S R U T S R U
A D 0.0548 0.0512 0.0411 0.0328 0.0274 0.0256 0.0205 0.0164
B D 0.0274 0.0256 0.0205 0.0164 0.0137 0.0128 0.0102 0.0082
A C 0.0137 0.0128 0.0102 0.0082 0.0069 0.0064 0.0051 0.0041
B C 0.0069 0.0064 0.0051 0.0041 0.0034 0.0031 0.0025 0.0020
SADDLE FEED
Inches/spindle revolution
CROSS SLIDE FEED
Inches/spindle revolution
External gears
Figure 3-4 Feed control levers on the apron
To power the saddle (longitudinal motion), move the power feed lever
to the RIGHT, then UP, as shown here. To power the cross slide, move
the lever LEFT and DOWN. Test for engagement/dis-engagement by
gently jogging the saddle and cross-slide handwheels. The split nut le-
ver, used only for thread cutting, cannot be engaged unless the power
feed lever is NEUTRAL, neither up or down.
Figure 3-3 External change gears
This is the same setup used for U.S. thread
cutting (see later in this section). Shown
here are 60T upper, 60T lower — the same
pairing used for threads such as 20 and 32
TPI. The other pairing recommended for
power feed, 30T upper/60T lower, is also
used to cut 24 and 48 TPI threads.
ALTERNATIVE GEAR ARRANGEMENTS
Small change gears can be installed with the hub facing out,
as Figure 3-8, lower gear. For the upper change gear, only,
this does not apply to gears larger than 42 teeth.

11PM-1440BV v3 2020-10 Copyright © 2020 Quality Machine Tools, LLC
FEEDSHAFT CLUTCH
The clutch shown in Figure 3-7 disengages the power feed if
the saddle or cross slide hits an obstruction when power feed-
ing, thus minimizing the potential for damage. This could be
the result of either an accidental event, or deliberately stopping
the saddle at a precise location set by the saddle stop, Figure
3-6.
The clutch comprises a pair of spring loaded steel balls bear-
ing on a detent disc driven by the saddle feed gearbox. Spring
pressure is adjusted by two set screws on either side of the
feed shaft, arrowed in Figure 3-7. Setting the spring pressure
is a process of aiming for the best compromise between too
high — damaging feed pressure — and too low, stopping pre-
maturely.
Setting the clutch to work reliably with the micrometer carriage
stop is a good example of such a compromise: start with low
spring force, then work up in small increments until the car-
riage stops in the same location (say ± 0.002”, assuming a
constant depth of cut and feed rate).
SADDLE STOP
The stop assembly, Figure 3-6, has a micrometer-style collar
graduated in 0.001 in. divisions. It can be clamped at any point
along the lathe bed (two M6 socket head screws on the under-
side secure the clamp plate to the block).
Figure 3-6 Saddle stop (representative)
Figure 3-7 Feedshaft clutch
THREAD CUTTING
External change gears
The large gears in Figures 3-3 and 3-8 are transposing gears,
120T and 127T. They allow a standard-thread leadscrew, in
this case 8 TPI, to cut metric threads. The transposing gears
are cut from a single steel blank.
KEY FACTS TO REMEMBER ...
TPI threads
See Figure 3-3. For inch thread cutting, the 120T smaller gear
is simply an idler, transferring the drive from the upper change
gear to the lower change gear.
Metric threads
The upper change gear engages the 127T gear, Figure 3-8.
The smaller of the transposing gears, 120T, drives the lower
change gear.
For metric threads the split-nut on the apron must be left
engaged throughout the entire process.
Figure 3-8 External gear setup for metric threads
The lower change gear is installed hub outward.
METRIC vs. U.S. THREAD SETUPS
The 127T/120T transposing gear is installed 127T to the out-
side for metric threads, 120T out for U.S. threads. This calls
for reversal of the gear’s ball bearing assembly — two ball
bearings on a shouldered bushing. The bushing has to be
tapped clear of the ball bearings, then re-installed the other
way around.
A time-saving suggestion: Remove the shouldered bushing
and part-o󰀨 the larger diameter portion. Re-install the smaller
diameter in the ball bearings. For the removed portion substi-
tute a separate plain collar. This will allow the transposing gear
to be installed either way with no additional e󰀨ort.

12PM-1440BV v3 2020-10 Copyright © 2020 Quality Machine Tools, LLC
Gear shifters
R-1 U-1 U-1 U-1 U-1 U-1 T-1 U-1 U-3
er
gear 60 60 60 60 40 40 30 40 60
er
gear 60 54 57 60 44 46 60 52 63
A-D 4 4-1/2 - 5 5-1/2 - 6 6-1/2 7
B-D 8 9 9-1/2 10 11 11-1/2 12 13 14
A-C 16 18 19 20 22 23 24 26 28
B-C 32 36 38 40 44 46 48 52 56
Figure 3-9 Threads per Inch (TPI)
Gear swapping
Any change to the drive train typically calls for one or both
of the upper and lower gears to be exchanged for a larger or
smaller gear. This will require the transposing gear pair to be
repositioned. The procedure for this is:
1. Use a 18 mm wrench to remove the hex nuts from the up-
per and lower gear shafts.
2. Remove the gears, washers, keys and bushing (lower gear
only).
3. While holding the gear support casting (quadrant) with one
hand, use a 16 mm wrench to loosen its anchor nut. Allow
the casting to swing downward.
4. Loosen the 16 mm hex nut securing the transposing gears
to the support casting.
5. Install the lower gear (for TPI threads the 120T gear is out-
side, for metric threads, inside).
6. Bring the transposing gears into mesh with the lower gear,
trapping a scrap of bond paper (letter stock) between the
two to hold them at the correct separation.
7. Tighten the transposing gears in position, then remove the
paper. Check for working clearance between the gears.
8. Install the upper gear.
9. Swing the gear support casting upward to mesh the 127T
gear with the upper gear, again using a paper scrap for
separation.
10.Tighten the gear support casting.
11. Lubricate the gears.
Gear shifters
R-4 U-4 S-3 T-4 U-1 R-3 T-1 U-3 U-1
er
gear 56 60 60 30 60 60 30 60 42
er
gear 60 60 60 60 60 60 60 60 63
A-D 7.0 6.0 - 5.0 - 4.5 4.0 - -
B-D 3.5 3.0 - 2.5 - 2.25 2.0 1.8 1.6
A-C 1.75 1.5 1.4 1.25 1.2 - 1.0 0.9 0.8
B-C - 0.75 0.7 - 0.6 - 0.5 0.45 0.4
Figure 3-10 Metric thread pitches (mm)
COMPOUND SETUP FOR THREAD CUTTING
Thread cutting on the lathe is unlike most other turning
operations, for two reasons: 1. The cutting tool must be
precisely ground with an included angle of 60 degrees
for most American and metric threads, and; 2. It is pref-
erable to feed the tool into the workpiece at an angle
so it cuts mostly on the left ank of the thread, Figure
3-11. The correct angle relative to the cross slide (zero
degrees) is debatable — should it be 29, 29-1/2 or 30
degrees? Many machinists prefer 29 degrees because
it holds the cutting tool marginally clear of the right ank
of the thread, close enough for cleanup of the ank while
at the same time avoiding appreciable rubbing.
CUTTING PROCEDURE FOR TPI THREADS
This procedure assumes that a single point thread cut-
ting tool will be used, and that the threading dial assem-
bly, Figure 3-13, has been pivoted forward to engage its
worm wheel with the leadscrew.
The threading dial cannot used for metric threads!
The split-nut on the apron must be left engaged
throughout the entire process.
For metric and UNC/UNF threads the tool is ground to
60o (included angle). It is installed so that its anks are
exactly 30oeither side of the cross axis, ideally with the
compound o󰀨set as Figure 3-11. Single-point threads
are cut in 10 or more successive passes, each shaving
a little more material o󰀨 the workpiece.
Figure 3-11 Setting up the compound for 30oinfeed

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GENERAL RULES FOR THE THREADING DIAL
1. Divide the TPI value by 2: If this gives an EVEN whole
number, example 12/2 = 6, re-engage at any line on the
dial, also mid-way between the lines.
1. If the ÷ 2 result is an ODD whole number, examples 10/2
= 5, 14/2 = 7, re-engage at any line on the dial, but NOT
mid-way between the lines.
To make the rst thread-cutting pass the leadscrew is run at
the selected setting (tables on this, and preceding pages), and
the carriage is moved by hand to set the cutting tool at the
starting point of the thread. With the tool just grazing the work-
piece, the split-nut lever is lowered to engage the leadscrew.
This can be done at any point, provided the split-nut remains
engaged throughout the entire multi-pass thread cutting
process.
When the rst pass is completed, the tool is backed out clear
the workpiece (using the cross slide), and the spindle is re-
versed to bring the saddle back to the starting point. The cross
slide is returned to its former setting, then the tool is advanced
a few thousandths by the compound for the next pass. Each
successive pass is done in the same way, each with a slightly
increased infeed setting of the compound.
Many users working on U.S. threads save time by disengag-
ing the split-nut at the end of each cutting pass, reversing the
saddle by hand, then re-engaging, usually by reference to the
threading dial.
If the TPI number is divisible by 2 re-engagement can be done
at any line on the threading dial.
For all other TPI numbers every engagement, including the
rst, must at the point where a specic line on the threading
dial comes into alignment with the datum mark. If not, the sec-
ond and subsequent passes will be out of sync. In some cas-
es, Figure 3-12, there is a choice of lines for re-engagement,
but in every case the process calls for careful timing. [NOTE:
Disengagement and re-engagement of the split-nut is not
applicable to metric threads].
Typical depths of cut per pass vary from an initial 0.005” or so,
to as little as 0.001”, even less. A nishing pass or two with
increments of only 0.0005” — or none at all, to deal with the
spring-back e󰀨ect, can make all the di󰀨erence between a too-
tight thread and one that runs perfectly.
Assuming that the compound is set over at between 29 and
30 degrees, the total depth of cut is approximately 0.69 times
the thread pitch, P (this equates to a straight-in thread depth of
0.6 times P). There may be a need for a few thousandths more
in-feed than 0.69P, almost certainly not less.
Figure 3-12 Threading dial visualization for selected U.S. threads
Minimize wear by swinging the dial indicator assembly away from the
leadscrew when not in use
2. If the TPI value is a whole number not divisible by 2, ex-
ample 7, re-engage on the start line, or any line at right
angles to it.
3. If the TPI value is fractional, but becomes a whole number
when multiplied by 2, example 4-1/2, re-engage only on
the start line, or its diametrical opposite.
If in doubt, re-engage on the start line!

14PM-1440BV v3 2020-10 Copyright © 2020 Quality Machine Tools, LLC
Figure 3-13 Threading dial
CROSS SLIDE & COMPOUND
The cross slide and compound have 10 TPI leadscrews, with
100-division graduated collars, Figure 3-14. Each division rep-
resents a “true” motion of 0.001”. On the cross slide dial, only,
this shows as 0.002” per division, meaning that a 0.001” depth
of cut reduces the diameter of the workpiece by 0.002”.
The collars also have 127-division metric graduations, display-
ing "true metric" motion of 0.02 mm per division on the com-
pound, 0.04 mm on the cross slide.
Figure 3-14 Cross slide and compound dials
TAILSTOCK
The tailstock leadscrew has a 10 TPI thread, with 4 inch travel.
Inch and metric graduated collars on the tailstock handwheel
read 0.001” and 0.02 mm per division. A transverse slot at the
narrow end of the internal taper (MT4) provides clearance for
drills and other devices with tang ends. To remove tooling from
the tailstock taper turn the handwheel counter-clockwise (han-
dle end view) until resistance is felt, then turn the handle a little
more to eject the tool. Conversely, to install a taper tool make
certain that the quill is out far enough to allow rm seating.
For taper turning the tailstock may be o󰀨set by adjusting set
screws on either side, Figure 3-15. To move the tailstock to
the back, for instance, the screw on the lever side would be
unscrewed, then the opposing set screw would be screwed in
to move the upper assembly. A clamp screw holds the tailstock
rmly against a transverse rib in the base casting. Loosen it if
necessary to allow o󰀨setting.
A visual indication of the o󰀨set is provided by a scale on the
back surface, but this is not a reliable measure for precise
work. In practice, the only way to determine the o󰀨set precisely
is to "cut and try' on the workpiece, or scrap stock, homing in
on the correct degree of o󰀨set in small increments.
The same issues arise when re-establishing "true zero" of the
tailstock, in other words returning it to the normal axis for rou-
tine operations. One way to avoid cut-and-try is to prepare in
advance a bar of (say) 1" diameter quality ground stock, with
precise center drillings at both ends (do this by indicating for
zero TIR in a 4-jaw chuck, not in a 3-jaw unless known to be
predictably accurate). The prepared bar can then be installed
between centers and indicated along its length.
Figure 3-15 Tailstock
LOCKING THE SLIDES
When face-cutting large diameter surfaces, for instance, it is
often desirable to lock the saddle. Less frequently it can be
helpful to lock, or at least sti󰀨en, sliding motion of the com-
pound, Figure 3-16.
If a DRO system is installed, the Y axis scale blocks access to
the cross slide lock screw.

15PM-1440BV v3 2020-10 Copyright © 2020 Quality Machine Tools, LLC
Figure 3-16 Saddle and compound lock screws
STEADY & FOLLOWER RESTS
The hinge-type steady rest, Figure 3-17, can be mounted any-
where along the lathe bed. It makes possible cutting opera-
tions on long, slender workpieces between centers, or held at
one end by chuck. The steady rest is often used in combina-
tion with the saddle-mounted follower rest, Figure 3-18. To set the ngers on the workpiece, rst swing open the upper
casting. Make certain that all three ngers are freely adjustable
by thumbwheel. If not, loosen and re-lock the set screws (ar-
rowed). Raise the two lower ngers to just touch the workpiece
— not deecting it — then close and secure the upper casting.
Lower the top nger to just touch the workpiece, clamp the
frame, then apply oil at the point of contact.
The follower rest, Figure 3-18, is secured to the saddle with
two 8 mm socket head screws. Adjust the follower ngers as
described for the steady rest.
Figure 3-17 Steady rest (representative)
Figure 3-18 Follower rest (representative)
GAP BED
An 8-3/16 in. long section of the bed at the headstock end
can be removed to allow turning of diameters up to 18-3/4 in.,
Figure 3-19.
To remove the gap insert back out the pusher screw one or
two turns, then remove the four large socket head screws se-
curing the insert to the bed. To minimize cosmetic damage, cut
through the paint and ller along the joint between insert and
bed using a sharp knife or pointed scraper.
Jack out the two taper pins using a 13 mm hex wrench.
Before re-installing the insert, be certain that all mating surfac-
es are scrupulously clean. Set the insert in place, lightly tap in
the two locating pins, then install the four large bolts (snug, but
not fully tightened). Jack the insert to the right with the pusher
screws to close the gap, if any, between the ground surfaces

16PM-1440BV v3 2020-10 Copyright © 2020 Quality Machine Tools, LLC
of the bed ways at the join (a visible parting line may be ac-
ceptable, but a discontinuity that snags the saddle is not). If a
satisfactory join cannot be achieved, it may be necessary to
remove and reinstall the insert from scratch.
Figure 3-19 Gap insert
Representative
insert
COOLANT SYSTEM
The coolant system is typically used with water-miscible
(emulsied) cutting uid. It can also be used with lightweight
neat cutting oil straight from the can. Synthetic cutting uids
are not recommended due to their potential for corrosion and
other undesirable e󰀨ects on the lathe and the coolant pump.
If you use water-miscible cutting uid, bear in mind that the
ratio of product to water is important — too much water causes
excessive corrosion and other problems. Check the mix from
time to time using a refractometer. If this is not available, make
up a small batch according to the product directions, then re-
place with a fresh batch when the old one becomes unusable
due to reduced performance, oil/water separation, or bad odor.
Disposal of used cutting uid can be a problem. It is about 95%
water, so its volume can be drastically reduced by evaporation
in an open tank. The residue may then be handled like any
other waste oil.
Figure 3-20 Coolant pump assembly, RH stand cabinet

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CHUCKS & FACEPLATE
The spindle nose on the PM-1440BV accepts D1-5 Camlock
chucks, faceplates and other work holding devices.
A D1-5 chuck or faceplate is held by six threaded studs, each
with a D-shape crosscut to engage a corresponding cam in the
spindle nose, Figures 3-21, 3-22. The function of the cams is
to pull the chuck backplate inward to locate its internal taper
rmly on the spindle nose.
Alongside each stud is a stop screw, the head of which ts
closely in a groove at the threaded end of the stud. The func-
tion of the stop screw is not to clamp the stud in place, but
instead to prevent it from being unscrewed when the chuck is
out on the bench.
TO INSTALL A CHUCK
Disconnect the 220V supply from the lathe!
D1-5 chucks and faceplates are heavy, some more than 30
lb. They will cause serious damage if allowed to fall. Even if a
chuck is light enough to be supported by one hand, the lathe
bed should be protected by a wood scrap, as Figure 3-23.
Some users add packing pieces, even custom-made cradles,
to assist “straight line” installation and removal.
All stop screws must be present & fully tightened!
Camlock action can jam any stud lacking a stop
screw — a serious problem.
Figure 3-21 D1-5 faceplate
Figure 3-22 Camlock stud
Before installing make certain that the mating surfaces of the
chuck/faceplate and spindle are free of grit and chips.
The cams on the spindle are turned with a square-tip wrench
similar to the chuck key (may be same tool in some cases).
Recommended procedure:
1. Select the high speed range Hto allow easier hand rotation
of the spindle.
2. Turn the spindle by hand, checking that all six cam markers
are at 12 o’clock.
3. While supporting its full weight, install the chuck without
tilting, see Figure 3-24, then gently turn each of the cams
clockwise — snug, rm, but not locked in this rst pass.
Figure 3-23 Protect the lathe bed
4. Check that each of the cam markers lies between 3 and
6 o’clock, between the two Vees stamped on the spindle,
Figure 3-25.
5. If any cam marker is not within the Vees, rst be sure
that there is no gap between chuck backplate and spin-
dle ange. Also, remove the chuck to inspect the studs —
Figure 3-24 Installing a Camlock chuck

18PM-1440BV v3 2020-10 Copyright © 2020 Quality Machine Tools, LLC
burrs can be a problem, hone if necessary. If there are no
visible problems, the stud in question may need ad-
justment as follows:
• Remove the stop screw from the stud.
• If the cam marker in question can’t get to the rst Vee (3
o’clock), back the stud OUT one full turn, then replace the
stop screw.
• If the cam marker goes beyond the second Vee (6 o’clock),
screw the stud IN one more turn, then replace the stop
screw.
• If the markers are correctly aligned, repeat the tightening
sequence as step 3, light force. Repeat the sequence two
more times, rst with moderate force, then fully tighten.
Figure 3-25 Cam in locked condition
TO REMOVE A CHUCK OR FACEPLATE
Disconnect the 220V supply from the lathe!
Protect the lathe bed, as Figure 3-23. While supporting its
weight, turn each of the cams to 12 o’clock, Figure 3-24, then
remove the chuck. If the chuck does not come free, try tapping
the backplate gently with a soft (dead blow) mallet.

19PM-1440BV v3 2020-10 Copyright © 2020 Quality Machine Tools, LLC
Section 4 SERVICING THE LATHE
Disconnect 220V power before any maintenance operation!
Remove all machining debris and foreign objects before lubricating ANYTHING! If need
be, any oil is better than no oil – but use the recommended lubricants when you can.
HEADSTOCK GEARBOX DRAIN & REFILL
Take time to prepare. 4 quarts is a lot of oil to clean up!
1. Run the lathe a few minutes to warm the oil if necessary.
2. Open the drive train cover left of the headstock.
3. Remove the ll plug on the top surface of the headstock,
GENERAL
Aside from abrasive particles and machining debris, lack of
proper lubrication is the main cause of premature wear. Ro-
tating parts are easy to lubricate, sliding parts are not. Gibs
are tightened for the best compromise between rigidity and
slideability, which means practically zero gap between the
ways. It is not obvious which are the bearing surfaces on the
various dovetail surfaces — some of the interfaces look like
bearing surfaces, but are simply narrow gaps.
Every few hours of operation: 1. Apply the recommended way-
oil with a dedicated short-bristle brush such as the type used
for applying ux; 2. Use a similar brush to apply oil or grease to
the leadscrews; 3. Apply oil to the ball oilers, see below.
The spindle runs on sealed, pre-lubricated roller bearings re-
quiring no routine attention.
Recommended lubricants
Gearboxes: ISO 68, such as Mobil DTE Heavy/Medium circu-
lating oil. Approximate quantities required:
Headstock 4 quarts
Saddle feed gearbox 2 quarts
Apron 1 quart
Ball oilers: ISO 68 way oil, such as Mobil Vactra No. 2, or
equivalent.
Machine ways (dovetails): ISO 68 way oil, such as Mobil
Vactra No. 2, or equivalent.
External change gears: light general purpose grease, NLGI
No. 2, or equivalent.
Leadscrews: ISO 68 way oil, such as Mobil Vactra No. 2, or
equivalent.
BALL OILERS
Use a pump-type oil can, preferably with a exible spout tipped
with a soft tube. The ID of the tip should be large enough
to seat on the oiler's brass ange, more than spanning the
spring-loaded steel ball. When the oil can tip is rmly pressed
onto the brass surface oil pressure will displace the ball, allow-
ing oil to ow into the bearing. Before oiling check that the ball
is not stuck – press it lightly with a probe.
Figure 4-1.
4. Place a drain pan (2-gallons minimum) on a stool or other
support at about the height of the chip tray.
5. Fold a sheet of card stock to make a Vee-shape drain
channel. This will be pressed against the headstock below
the drain plug, angled downward into the drain pan; trim
the upstream end of the Vee so that it seals against the
headstock.
6. With the drain channel in place, remove the drain plug, Fig-
ure 4-2.
7. Allow the oil to drain completely. Replace the drain plug,
then add just a few ounces of oil.
8. When satised that the headstock is oil-tight, add oil to the
halfway mark on the sight glass, Figure 4-3 (about 4 qts).
9. Replace the ll plug.
Figure 4-1 Headsto
Figure 4-3 Headstock sight glass
Figure 4-2 Headstock
drain plug (1)

20PM-1440BV v3 2020-10 Copyright © 2020 Quality Machine Tools, LLC
SADDLE FEED GEARBOX DRAIN & REFILL
Make a card-stock Vee channel as described for draining the
headstock. Run the lathe for a few minutes to warm the oil if
necessary. Remove the gearbox ll plug, Figure 4-4 (2). With
the Vee channel in place, remove drain plug (3) and allow the
gearbox to empty completely. Replace the drain plug. To rell
the gearbox use a funnel attached to a exible plastic tube in-
serted into the ll hole. Add oil to the halfway mark on the sight
glass on the front panel of the gearbox (about 2 qts).
APRON GEARBOX DRAIN & REFILL
Remove the ll plug, Figure 4-5. Remove the drain plug, Fig-
ure 4-6, and allow the apron to empty completely. Replace
the drain plug. Add oil to the halfway mark on the sight glass
(about 1 qt).
Figure 4-4 
Figure 4-6 Apron sight glass & drain plug
BALL OILERS
See the general note on the previous page.
Figure 4-7 Saddle, cross slide and compound oilers
A 9th oiler, not shown, is above the saddle handwheel
Figure 4-5 
Figure 4-8 Tailstock oilers