Proxxon PD 400 Quick start guide

Commissioning Manual
PD 400 CNC-ready
NO 24 504

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Commissioning Manual PD 400 CNC-ready
1. Something general in advance: ..............................................................................3
2. The technology of your PD 400 CNC-ready at a glance .........................................4
3. Scope of supply......................................................................................................4
4. View of the machine with its elements....................................................................5
5. Technical data........................................................................................................6
5.1. Lathe:.....................................................................................................................6
5.2. Drives of the tool axes............................................................................................7
5.2.1. Spindle drive Z-axis................................................................................................7
5.2.2. Spindle drive X-axis................................................................................................7
5.2.1. Pin assignment of the Sub D-9 connector...............................................................7
6. Unpacking and setting up the machine...................................................................8
7. Basic tips on setting up and assembling the machine.............................................9
7.1. Room EMERGENCY Off........................................................................................9
8. Basics of working with the machine........................................................................9
8.1. Fundamentals on turning and the PD 400 CNC-ready lathe.................................10
8.1.1. Straight turning.....................................................................................................10
8.1.2. Grooving and parting............................................................................................10
8.2. Various cutting tools and their properties..............................................................11
8.2.1. Roughing tools (1)................................................................................................11
8.2.2. Finishing or pointed tools (2) ................................................................................11
8.2.3. Right (3) or left cutters..........................................................................................11
8.2.4. Parting tools (4)....................................................................................................11
8.2.5. Threading tools (5) ...............................................................................................11
8.2.6. Inside turning tools (6)..........................................................................................11
8.3. Inserting the cutting tool in the tool holder ............................................................12
8.4. Clamping in the lathe chuck..................................................................................13
8.5. Machining longer work pieces with tailstock and lathe centre...............................13
8.6. Determining the correct spindle speed..................................................................14
8.7. Determining the spindle speeds ...........................................................................14
8.8. Shifting the drive belt............................................................................................15
8.1. Direction of rotation switch....................................................................................15
9. Service and Maintenance.....................................................................................15
9.1. General ................................................................................................................16
9.2. Cleaning...............................................................................................................16
9.3. Lubrication............................................................................................................16
9.4. Adjusting the play of the guides............................................................................17
9.4.1. Adjusting the play of the guide of the cross slide..................................................17
9.4.2. Adjusting the play of the guide of the support.......................................................17
9.5. Main spindle.........................................................................................................17
9.6. Care and maintenance checklist...........................................................................18
10. Disposal: ..............................................................................................................18
11. Compilation of safety notes ..................................................................................18
12. EC Declaration of Conformity...............................................................................20
13. List of components and exploded views ...............................................................21
13.1. Assembly group 01 Headstock.............................................................................22
13.2. Assembly group 02: Bed with drive for Z axis.......................................................26
13.3. Assembly group 03: Support with drive for X axis.................................................28
13.4. Assembly group 04: Tailstock...............................................................................30

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WARNING
Read all safety warnings, instructions, illustrations and specifications
provided with this power tool.
Failure to follow all instructions listed below may result in electric shock, fire and l or
serious injury.
Save all warnings and instructions for future reference.
The term "power tool" used inthe safety instructions refers to mains-operated power tools
(with mains lead) or battery-operated power tools (without mains lead).
1. Something general in advance:
Please note:
The information given and knowledge imparted in this manual are indispensable for the
safe commissioning and operation of the machine and the control system!
Therefore, read the manual carefully and make sure that you have understood the
contents!
WARNING
Familiarise yourself with the potential dangers of the machine before commissioning the
selected software control machine tool configuration! Observe all safety instructions from
this machine tool and from the manufacturer of the selected control. Note that the user
alone is responsible for safety when operating the application.
DANGER
In case of damage, do not touch any parts of the installation, disconnect the power supply
and send the parts concerned to a qualified service workshop, ideally to our central
service.
WARNING
Observe the electrical values specified in the technical data for controlling the stepper
motors of the machine tool. Make sure that the electrical configuration of the control is
compatible with the electrical data of the motors!

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2. The technology of your PD 400 CNC-ready at a glance
Dear User,
With the PD 400 CNC-ready lathe, you have acquired a powerful, precise processing
machine that meets high demands on operability, precision and reliability:
The mechanical basis is the proven PD 400 lathe from PROXXON.
However, the electronic control of the feeds of the two tool axes with a computer
comprehensively extends the possibilities of a conventionally, i.e. manually controlled
lathe:
The handwheels of the PD 400 are replaced by electric stepper motors, whose force is
converted into feed of the tool slides by means of high-precision recirculating ball screws.
The stepper motors are controlled by the selected CNC control, which is "operated" and
monitored by the control computer.
3. Scope of supply
1 pc. Lathe with attached stepper motors
1 pc. Three-jaw chuck (Ø 100 mm)
1 pc. Travelling centre punch
1 pc. Gear rim drill chuck (up to 10 mm clamping)
1 pc. Operating tool
1 pc. Multiple steel holder with 2 steel holder elements
1 pc. Rotary chuck guard

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4. View of the machine with its elements
1
Main spindle
2
Lathe chuck
3
Motor
4
Gearbox
5
Machine base
6
Tailstock
7
Drive for Z axis
8
Spindle for Z axis
9
Position switch Z axis
10
Drive for X axis
11
Spindle for X axis
12
Position switch X axis
13
Support
14
Cross slide
15
Multiple tool holder
16
Tool holder element
17
Sleeve
18
Sleeve adjusting wheel
19
Clamping screw for sleeve
20
Clamping screw for tailstock
21
Direction of rotation switch
22
Indicator light
023
Speed step switch
24
Speed table
25
Flange surface for milling unit PF 230/250/BL
26
Travelling lathe centre
27
Chuck guard
28
Cutting tool
29
Gear rim drill chuck
30
Key for drill chuck
31
Key for lathe chuck
32
Allen keys
33
Drill holes for fastening to table

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5. Technical data
5.1. Lathe:
Length between centres:
400 mm
Height of centres:
85 mm
Maximum work piece diameter:
116 mm
Machine base:
Cross-ribbed surface, high-quality cast iron with
ground prismatic guide
Spindle:
Main spindle, supported with 2 adjustable taper
roller bearings
Spindle receiver:
MK3
Spindle drill hole:
20.5 mm
Spindle concentricity:
5/1000 mm
Chuck (series):
Precise 3 jaw chuck, centrically clamped, 100 mm
diameter
Sleeve receiver:
MK2, retractable sleeve with scale
Spindle speeds:
Adjustable with switch (two-stage) and by shifting
the drive belt (three-stage)
Switch setting 1:
80 / 330 / 1400 rev/min
Switch setting 2:
160 / 660 / 2800 rev/min
Motor rating:
550 W
Motor type:
Induction motor
Size (L x D x H):
900 x 400 x 300 mm
Weight (complete):
approx. 45 kg

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5.2. Drives of the tool axes
5.2.1. Spindle drive Z-axis
Recirculating ball screw with 4mm pitch
Effective diameter 12 mm
Traverse path: 300mm
Limit switch position: left
Motor:
Current: 1,8 A
Holding torque: 50 Ncm
5.2.2. Spindle drive X-axis
Recirculating ball screw with 2 mm pitch
Effective diameter 8 mm
Traverse path: 70mm
Limit switch position: in front
Motor:
Current: 1,8 A
Holding torque: 50 Ncm
5.2.1. Pin assignment of the Sub D-9 connector
Coil 1a
Coil 1b
Coil 2a
Coil 2b
Limit Switch

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6. Unpacking and setting up the machine
6.
Please note:
The information given in this manual and the knowledge it conveys is indispensable for
the safe commissioning and the safe operation of the machine and the controls!
Please read the manual attentively and make sure you have understood the contents!
Carefully unpack the individual components from the Styrofoam packaging. Please
check for completeness of the delivery by using the list in the chapter "Scope of
Supply".
Caution!
Do not grasp the gear case, the motors, or the cover of the motor to lift the machine
out of the Styrofoam packaging. The plastic caps could break.
Please enlist the aid of a helper to lift your PD 400 CNC-ready out of the package as
illustrated in the figure on the right.

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7. Basic tips on setting up and assembling the machine
•The machine may only be set up and operated in dry and well ventilated rooms.
•The installation surface must be level and sufficiently stable to absorb the
vibrations that occur during operation. For this purpose, the machine must be fixed
to a firm, level surface using the holes provided.
•Please ensure that the mains cable is outside the danger zone and is not crushed
or otherwise damaged!
•Mount the lathe chuck on the main spindle with the 3 corresponding screws,
making sure that the seat of the chuck is free of dirt and that the chuck is perfectly
centred.
•Please note:
All bare metal parts of the machine are preserved with a corrosion protection when
delivered. This protection does not serve as lubrication, but only as preservation,
and must therefore be washed off before first use, e.g. with a petroleum-soaked
and non-fluffy cloth.
•All guides must be checked from time to time and, if necessary, adjusted in rare
cases due to wear. (See chapter " Adjusting the play of the guides ").
•Afterwards, the bare guides and spindles must be well oiled with a suitable
machine oil.
7.1. Room EMERGENCY Off
An EMERGENCY Off switch that disconnects the power supply in the entire room must
be installed in the room where the machines are operated. This red/yellow coloured
mushroom-shaped pushbutton must be easily accessible and arranged far enough
away from the possible hazardous area.
8. Basics of working with the machine
Caution!
Before switching on for the first time, check that the screws of the lathe chuck are
correctly tightened, that the lathe chuck key is not inserted and that the support has
sufficient distance to the lathe chuck.
Caution!
Please note that due to the construction type, the motor can become very hot if left in
idle operation for a longer period. This is not an indication for a motor defect; still, it is
recommended to avoidthis operating stateand not to leave the machine unnecessarily
in idle operation.

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8.1. Fundamentals on turning and the PD 400 CNC-ready lathe
8.1.1. Straight turning
Straight turning is the type of turning whereby the cutter moves on a path parallel to
the work piece axis, the "longitudinal feed".
The cutting depth, also called "infeed" is the amount by which the cutter dips deeper
into the material for every turning cycle.
"Feed" is the distance per revolution of the work piece which the tool travels on its path.
The cutting cross-section is therefore the product of feed and cutting depth. Straight
turning is the most common machining type.
8.1.2. Grooving and parting
Grooving is the manufacture of fine grooves through radial infeeding of the cutting tool
without longitudinal feed.
If the tool is infeed so much that the work piece is thus "cut through" (meaning up to
the rotary axis or the centre of the work piece), then this is called "parted".
In principle:
The height of the cutting edge of the parting tool must be adjusted precisely to the
height of the centre of the work piece! Also, the tool must be clamped as short as
possible:
Too much free length always means deformation and susceptibility to vibrations! This
naturally applies to straight turning as well.
Use a low speed and lubricate the tool if possible with a bit of machine oil.

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8.2. Various cutting tools and their properties
For various work tasks there are special tools that are optimally co-ordinated to their
respective intended use due to their form. The right choice of tool is thus not only
essential for the perfect quality of the work result, but some machining can only be
done with certain tool forms from the outset.
We will briefly introduce the most important forms:
8.2.1. Roughing tools (1)
are used to wear off as much swarf as
possible in a short time (regardless of the
finish of the work piece surface).
8.2.2. Finishing or pointed tools (2)
are used to achieve a clean surface.
8.2.3. Right (3) or left cutters
are used for longitudinal and face turning
as well as for boring acute angles in right
or left machining direction.
8.2.4. Parting tools (4)
are used to groove flutes and to separate the work pieces.
8.2.5. Threading tools (5)
are used to cut external threads.
8.2.6. Inside turning tools (6)
for boring, i.e. to manufacture cylindrical hollow spaces

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8.3. Inserting the cutting tool in the tool holder
The basic equipment of the PD 400 CNC-ready includes a multiple tool holder
consisting of tool holder block 1 and two tool holder elements 2.
The tool holder elements can be adjusted in height: Turn the knurled screw 5 up or
down until the tool centre is exactly in the centre, meaning at the same height as the
work piece axis. The exact height setting is very important.
This is the only way to guarantee the optimal geometrical conditions at the cutting
edge. Otherwise vibrations and a bad work result would be the result.
The position set in this way can be "memorized" by tightening with knurled screw 6 and
can be reproduced by repeatedly inserting the tool holder in the dovetail guide.
Often different cutting tools are required for different work processes. If they are
already "pre-mounted" in the tool holder and adjusted correctly, they can be easily
exchanged in the dovetail guide after loosening screw 7.
The correct height is set automatically when the knurled screw hits the top side of the
tool holder.
1. Insert cutting tool 3 in tool
holder element 2. Firmly
tighten both screws 4.
2. Insert tool holder element in
tool holder block 1. Adjust
the height of the cutting tool
with nut 5 and tighten with
nut 6.
3. Please adjust the height of
the cutting edge with the
lathe centre in the tailstock.
4. Clamp tool holder element
with screw 7.
Note:
The entire holding block can be swivelled after release screw 8.

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8.4. Clamping in the lathe chuck
Caution!
Please comply with the enclosed operating
instructions of the chuck manufacturer as
necessary!
Caution!
If work pieces are only clamped in the lathe
chuck without counter-bracket by the tailstock,
the projection may not be greater than the
three-fold diameter of the material (L = 3 x D),
see figure at right.
8.5. Machining longer work pieces with tailstock and lathe centre
Longer work pieces (chuck projection
greater than the 3-fold work piece
diameter) must be held at the right end by
the tailstock and the travelling lathe
centre. To do so, please affix a centring
hole on the right side:
1. Carefully face turn the right face side.
2. Insert drill chuck 1 (picture right) in
the tailstock and clamp the centring
drill.
3. Move the tailstock up to the work
piece and fix with clamping screw 2.
4. Switch on the machine and create
the centring hole using the sleeve
feed (hand wheel 4).
You can now replace the drill chuck with
the travelling lathe centre. Place the
centre in the centring hole and carefully
infeed until there is absolutely no play.
Now fix the sleeve with toggle 3.

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8.6. Determining the correct spindle speed
The cutting speed is a decisive parameter during machining. Too high or too low cutting
speeds affect the good end result, so the choice of spindle speed –which is decisive
for the cutting speed –is very important for a good surface and clean metal removal.
Another determining factor is the diameter of the work piece: the greater it is, the
greater the relative speed is at the circumference at constant speed. The relation is
characterised by the following equation:
n = Vc * 1000/ (D * 3.14)
whereby:
n: Rotational speed
Vc: Cutting speed
D: Diameter
The table on the gear case of the machine offers help in choosing the right cutting
speed. For known cutting speed "Vc" and known work piece diameter "D", the
necessary spindle speed "n" can be calculated.
An example:
An aluminium work piece with a 30mm diameter will be machined. The necessary
cutting speed according to the table is 100–180m/min. We will calculate 132m/min.
n = 132 x 1000/ (30 x 3.14) = 1400 rev/min
This result can be read directly in the table on the gear case.
8.7. Determining the spindle speeds
By combining the speed step switch pos. 23 (Fig. 1) and the position of the belt in the
machine's gear box, six main spindle speeds from 80 to 2800 rpm can be selected:
The specifications refer in each case to position I and II of the speed step switch.

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8.8. Shifting the drive belt
The spindle speed can be changed by shifting the motor (multiple contact switch 1Fig.
4). The speed is halved or doubled. On the other hand, the speed can be changed by
shifting the drive belt in the spindle box at the left.
1. Switch off the CNC control at the mains
switch and open the gear case with the
Allen key.
2. Loosen clamping screw 1 by ½ a turn.
3. Use the Allen key 2 to turn screw 3 to
the left. This releases the intermediate
belt pulley 4.
4. Now change the belt according to the
graphic shown below.
5. Use the Allen key 2 to turn screw 3 to
the right to tension the belt again.
6. Remove Allen key 2 and tighten
clamping screw 1.
7. Close the gear case and put the
machine into operation.
8.1. Direction of rotation switch
Your CNC machine no longer has a separate mains switch
as it is controlled directly via control electronics.
However, during normal work, make sure that the direction
of rotation switch of the machine (shown in the figure on
the right) is not in the "0" setting, but is set to the desired
direction of rotation.
Otherwise the machine will not start.
That is why it also may not be set to "0" during a machining
procedure, as the spindle movement will be interrupted.
9. Service and Maintenance
Attention!
During all maintenance and cleaning work, make sure that the machine cannot start
up accidentally!
If necessary, make sure that the mains cable is disconnected from the control unit and
that the direction of rotation switch (see page 15) is in the middle position "0".

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9.1. General
Please keep the machine clean and handle it with care. Keep in mind that a "healthy"
mechanical system is decisive for the quality of the work result.
The guides in particular play an important role here: they are important machine
elements and must be treated with particular care.
Basically, machine maintenance includes cleaning after each use and regular oiling
and lubrication.
9.2. Cleaning
For cleaning e.g. chips etc. please use a hand brush or a paint brush. Please make
sure that the chips do not get into the guides or other moving parts.
Of course you can also use rags. However, these should not be linty in order to avoid
soiling the guides.
A vacuum cleaner is also suitable for removing the chips!
Never blow off the machine using compressed air: Dust and above all swarf can
be blown into guides or other moving parts and damage them!
When using cleaning agents, make sure the saturated wiping cloths are disposed of in
an environmentally-compliant manner. Do not dispose of in household waste.
9.3. Lubrication
Grease or oil all parts according to the
lubrication schedule. When oiling the
sliding surfaces, move the carriages
back and forth by hand several times
so that oil can run into the guides.
A = Oil/lubricate before every use
B = Oil /lubricate monthly
The regular and careful lubrication
will decisively reduce friction between
two moving parts and will thus
contribute to a long service life of the
guide and a good mechanical
condition of the machine.
To properly apply the lubricant, use
an oil can or a lint-free cloth saturated
with oil or grease. Please treat the guides and all moving and blank parts in the same
manner.
Please also comply with the instructions of the lubricant manufacturers!

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9.4. Adjusting the play of the guides
9.4.1. Adjusting the play of the guide of the cross slide
Even if the guides are regularly oiled, cleaned and properly
adjusted, the guides will show play after some time.
1. Release the counter nuts 1 (Fig. 18) of the
adjusting screws for upper carriage 2, turn in all
adjusting screws 3 evenly until the play is
eliminated and then retighten the counter nuts.
Please note:
The guide can be clamped with the screw 4.
9.4.2. Adjusting the play of the guide of the support
1. Repeat the same procedure for the cross slide 4.
Note: The guide can be clamped with the help of
screw 5.
2. Turn the machine upside down and unscrew the
threaded pin 1 (pic. Right) somewhat.
3. Lightly retighten clamping screws 2 to reduce play.
4. Check if the support can still be moved easily. The
drive motors could stall if the support is too stiff.
These will then emit "peeping" noises. In this case,
increase play somewhat.
9.5. Main spindle
The bearing assembly of the spindle through 2 taper rolling bearings is maintenance-
free for at least 6,000 hours at minimum speed and 1,800 hours at maximum speed. If
there is a small amount of play after this time, the bearings can be readjusted by a
specialist or in our central service.
2 4 1 3

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9.6. Care and maintenance checklist
Some elements affect the precision and work safety and must therefore be checked
regularly.
Here the following checklist for this purpose:
•Guides –clean and dry?
•Spindles free of machining residues ?
•Fastening screws are tight?
•Alignment: Are tables at right angles?
•Open the spindle covers for inspection: must swarf be removed by
vacuuming?
If required, the following maintenance activities are necessary:
•Clean the shafts, rub them dry, open the covers and clean or oil the spindle
system.
•Readjust the guides in case the carriages have play
•Rub aluminium surfaces with acid-free oil.
If the CNC machine will be decommissioned for a longer period of time, it should be
stored in a dry room at a minimum temperature of 5°C.
A cover to protect from dust and environmental effects is sensible.
10. Disposal:
Please do not dispose of the device in the household waste! The device contains valuable
substances that can be recycled. If you have any further questions, please contact your
municipal disposal company or other appropriate municipal institutions.
11. Compilation of safety notes
As with any other machine, there are some things that need to be observed when
operating the CNC lathe PD 400 CNC-ready so that dangers to humans and the
environment cannot occur.
In this context, please also observe the separately enclosed pamphlet with the safety
notes.
Special noise protection This can be achieved through ear protection, a protective
cell, or a closed room. Also, clamp the tools short so they
do not vibrate so strongly

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User group Persons above the age of 14 may use the system;
instructions on safety and compliance with the safety
notes is always required.
Caution!
Risk of injury! Always keep your fingers away from the rotating work
piece while turning! Never measure the work piece during
operation with a sliding calliper or similar! Do not process
the work piece during operation with a rasp or sandpaper!
Setting up the
workplace: No spatial narrowness
EMERGENCY Off push button in the room
Vacuum cleaner, permanently installed
PC and machine next to each other,
Connecting cable, max. 1.5m
User group Technically capable persons who are at least 14 years of
age.
Familiarize yourself using the documents or by being
instructed.
Machining unit Due to the safety regulations, a machining unit for clamping
processing is delivered.
Changing work pieces Please observe at all costs that the machine is protected
against unintentional actuation while changing the tools or
clamping work pieces in the respective clamping device!
When changing the tools, the mains power input for the machining unit must be
removed from the mains socket!
Clamp the lathe tool as short as possible!
Eye and
contact protection Wear protective goggles in the immediate vicinity and make
sure that the chuck guard is in the correct position when
operating the machine.
.
Software safety measures:
Locking and stopping
the machine: Machining, or movement, can be interrupted at any time
(software STOP):
•By pressing any key of the alphabetic and numeric keypad or any mouse button.
•Activate the switch/pushbutton "Lock" at the CNC control MCS to the "Lock"
position.

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12. EC Declaration of Conformity
We herewith declare in sole responsibility that the following designated product in the
design which we have marketed complies with the principle safety and health
requirements of the applicable EU Directive.
This declaration shall lose its validity if unauthorised changes were made to the
system.
Adress: Proxxon S. A.
Härebierg 6-10
LU-6868 Wecker
Product designation CNC Lathe
Type designation PD 400 CNC-ready
Article number 24504
Applicable Guidelines and Standards:
EC EMC Directive 2004/108/EG
DIN EN 55014-1/08.2018
DIN EN 55014-2/01.2016
DIN EN 61000-3-2/03.2017
DIN EN 61000-3-3/03.2014
EC Machinery Directive 2006/42/EG
DIN EN 62841-1/07.2016
RoHS-Directive 2011/65/EU
Jörg Wagner
14 th of December 2022
Machine Safety Department
The CE document authorized agent is identical with the signatory.