Sealey Sm3002.v2 User manual

INSTRUCTIONS FOR

METAL WORKING LATHE

MODEL NO:

SM3002.V2

Original Language Version SM3002.V2 Issue: 4 - 13/02/12

INSTRUCTIONS FOR:

METAL WORKING LATHE

MODEL: SM3002.V2

Thank you for purchasing a Sealey product. Manufactured to a high standard this product will, if used according to these instructions

and properly maintained, give you years of trouble free performance.

1. SAFETY INSTRUCTIONS

IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS AND

CAUTIONS. USE THIS PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY

CAUSE DAMAGE AND/OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.

1.2. GENERAL SAFETY

 WARNING!Disconnect the lathe from the mains power and ensure that the chuck is at a complete standstill before attempting to change

accessories, service or perform any maintenance.

 Maintain the lathe in good condition (use an authorised service agent).

 Replace or repair damaged parts. Use recommended parts only. Unauthorised parts may be dangerous and will invalidate the warranty.

 Locate the lathe in a suitable area. Ensure that the mounting surface is flat and firm. Keep the area clean and tidy and free from unrelated

materials, and ensure that there is adequate lighting.

 Keep the lathe clean for best and safest performance.

 WARNING! Before each use check that chuck, cutting tool and tailstock are secure and not worn or damaged. If any part of the lathe is

worn or damaged replace immediately.

 WARNING! Keep guard and holding fixings in place, tight and in good working order. Check regularly for damaged parts.

A guard that is damaged or missing must be repaired or replaced before the tool is next used. The safety guard is a mandatory fitting when

the lathe is used in premises covered by the Health & Safety at Work Act.

 Remove adjusting keys and wrenches from the lathe and its vicinity before turning it on.

 WARNING! Wear approved safety eye protection and, if oil mist is generated, respiratory protection.

 Remove ill fitting clothing. Remove ties, watches, rings and other loose jewellery and clothing, and contain long hair.

 Keep hands and body clear of the workpiece when operating the lathe.

 Maintain correct balance and footing. Ensure that the floor is not slippery and wear non-slip shoes.

 Keep children and unauthorised persons away from the work area.

 WARNING! DO NOT switch on the lathe whilst the cutting tool is in contact with the workpiece. Bring the cutting tool gradually to the workpiece.

 Avoid un-intentional starting of the lathe.

 DO NOT use the lathe for a task it is not designed to perform.

 DO NOT allow untrained persons to operate the lathe.

 DO NOT get the lathe wet or use in damp or wet locations, or areas where there is condensation.

1.1. ELECTRICAL SAFETY

WARNING! It is the responsibility of the owner and the operator to read, understand and comply with the following:

You must check all electrical products, before use, to ensure that they are safe. You must inspect power cables, plugs, sockets and any other

connectors for wear or damage. You must ensure that the risk of electric shock is minimised by the installation of appropriate safety devices. A

Residual Current Circuit Breaker (RCCB) should be incorporated in the main distribution board. We also recommend that a Residual Current

Device (RCD) is used. It is particularly important to use an RCD with portable products that are plugged into a supply which is not protected

by an RCCB. If in any doubt consult a qualified electrician. You may obtain a Residual Current Device by contacting your Sealey dealer.

You must also read and understand the following instructions concerning electrical safety.

1.1.1. The Electricity at Work Act 1989 requires all portable electrical appliances, if used on business premises, to be tested by a qualified

electrician, using a Portable Appliance Tester (PAT), at least once a year.

1.1.2. The Health & Safety at Work Act 1974 makes owners of electrical appliances responsible for the safe condition of those appliances

and the safety of the appliance operators. If in any doubt about electrical safety, contact a qualified electrician.

1.1.3. Ensure that the insulation on all cables and on the appliance is safe before connecting it to the power supply. See 1.1.1. and 1.1.2.

and use a Portable Appliance Tester.

1.1.4. Ensure that cables are always protected against short circuit and overload.

1.1.5. Regularly inspect power supply cables and plugs for wear or damage and check all

connections to ensure that none are loose.

1.1.6. Important: Ensure that the voltage marked on the appliance matches the power supply

to be used and that the plug is fitted with the correct fuse - see fuse rating at right.

1.1.7. DO NOT pull or carry the appliance by the power cable.

1.1.8. DO NOT pull the plug from the socket by the cable.

1.1.9. DO NOT use worn or damaged cables, plugs or connectors. Immediately have any faulty

item repaired or replaced by a qualified electrician. When a BS 1363/A UK 3 pin plug is

damaged, cut the cable just above the plug and dispose of the plug safely.

Fit a new plug according to the following instructions (UK only).

a) Connect the GREEN/YELLOW earth wire to the earth terminal ‘E’.

b) Connect the BROWN live wire to the live terminal ‘L’.

c) Connect the BLUE neutral wire to the neutral terminal ‘N’.

d) After wiring, check that there are no bare wires, that all wires have been correctly connected, that the cable outer

insulation extends beyond the cable restraint and that the restraint is tight.

Double insulated products, which are always marked with this symbol , are fitted with live (brown) and neutral (blue) wires only.

To rewire, connect the wires as indicated above - DO NOT connect either wire to the earth terminal.

1.1.10. Products which require more than 13Amps are supplied without a plug. In this case you must contact a qualified electrician to ensure

that a suitably rated supply is available. We recommend that you discuss the installation of an industrial round pin plug and socket

with your electrician.

1.1.11. If an extension reel is used it should be fully unwound before connection. A reel with an RCD fitted is preferred since any appliance

plugged into it will be protected. The cable core section is important and should be at least 1.5mm², but to be absolutely sure that the

capacity of the reel is suitable for this product and for others which may be used in the other output sockets, we recommend the use

of 2.5mm² section cable.

RECOMMENDED

FUSE RATING: 5AMP

Original Language Version SM3002.V2 Issue: 4 - 13/02/12

Precision built metal working lathe, ideal for the small workshop, professional or home engineer and model maker. Powered by a 300Watt motor

this compact unit features variable speed reversible drive and powered cutting facility for right and left hand threads. Supplied with self centring

three jaw chuck, four-way tool post, swarf tray and rear splash guard. Complies with Safety of Machinery (Safety) Regulations 1992 (and

amendments), is fully CE approved and supplied with emergency stop button and chuck guard.

An optional stand is available, order Model No. SM3002ST.

2. INTRODUCTION & SPECIFICATION

Motor: ...........................300W - 230V 50Hz

Spindle Speed Range: ...................100-2500rpm

Distance Between Centres: ................... 300mm

Centre Height: .............................. 90mm

Max. Workpiece Diameter:.................... 180mm

Spindle Bore: ............................... 20mm

Spindle Taper: ............................... MT3

Tailstock Taper:................................MT2

Cross Slide Travel: ........................... 65mm

Leadscrew: ................................. Metric

Dimensions: ....................... 300x300x830mm

Weight: ..................................... 40kg

Specification:

 WARNING! DO NOT use the lathe where there are flammable liquids, solids or gases such as petrol, paint solvents, waste wiping rags etc.

 DO NOT operate the lathe if any parts are missing or damaged as this may cause failure and/or personal injury.

 DO NOT lift or remove the chuck guard whilst the lathe is in use.

 DO NOT touch the workpiece close to the cut as it will be very hot. Allow it to cool first.

 DO NOT leave the lathe running unattended.

 DO NOT operate the lathe when you are tired or under the influence of alcohol, drugs or intoxicating medication.

 When not in use, switch off the lathe and isolate it from the power supply.

3. CONTENTS & ASSEMBLY

Contents description:

Lathe

2 Handwheel Handles (with bolts and nuts)

Tailstock Centre

3 External Chuck Jaws

6 Gears (30, 35, 2 x 40, 50 & 60 Teeth)

4 Rubber Feet

4 Screws

Swarf Tray

1 Chuck Key

4 Hex Keys

2 Spanners

2A Fuse

 Machine Oil

fig.1

WARNING! Safe handling will require two people.

3.1. Unpack the product and check that all components and tools are present and undamaged. If any problem is noted contact your supplier

immediately.

3.2. The machine has been coated with grease to protect it in shipping. Remove the coating with commercial degreaser, kerosene or similar

solvent before use. After degreasing coat the machined surfaces with machine oil.

3.3. Position the lathe on a sturdy workbench or on the optional stand (SM3002ST).

The lathe may be mounted on the rubber feet provided or bolted directly to the

workbench through M6 clearance holes dimensioned as in fig. 2.

3.4. Take the the two handles and drop a bolt through each one. Screw a nut to the bolt until

it touches the handle, then back it off approximately half a turn so that the handle rotates

freely on the bolt.

3.5. Screw the bolt of one handle into the saddle feed handwheel (fig. 1.6) and the other into the tailstock feed handwheel (fig. 1.3). in each

case, lock the bolt in place with the nut, ensuring that the handle can still rotate freely on the bolt.

3.6. The cross-slide feed handle (fig. 1.5) is fitted reversed for transit. Remove the handle and refit the correct way round.

4. SET-UP AND OPERATION

It is assumed that the operator has experience of machining practice and these instructions are intended only to describe the

features of the lathe. If you have no experience of machining, it is recommended that you undertake training before using this machine.

WARNING! Before operating the lathe, ensure that you are wearing approved safety goggles to protect yourself from swarf and

metal particles. If using cutting oil or coolant, a face mask may be necessary, to avoid breathing any vapour generated. Ensure

that all other safety instructions in Section 1 are followed carefully.

4.1. Initial start-up.

4.1.1. Check that the forward/reverse switch (fig.3.B) is in the Off position and that the speed control (fig.3.A) is on zero.

4.1.2. Set the high/low range lever (fig.4.A) to Low and the automatic feed lever (fig.5.A) to disengaged - turn anti-clockwise.

4.1.3. Confirm that the cross-slide is well clear of the chuck and that all keys, spanners etc. are clear of the machine.

fig.3 fig.4 fig.5

fig.2

Original Language Version SM3002.V2 Issue: 4 - 13/02/12

Thread Gear Size (Teeth)

Pitch A B C D Dial

0.4 20 50 40 60 1, 3, 5 or 7

0.5 20 50 - 60 Any

0.6 40 50 30 60 Any

0.7 40 50 35 60 1, 4 or 5

0.8 40 50 40 60 1 or 5

1.0 20 60 - 30 Any

1.25 50 40 - 60 1, 3, or 5

1.5 40 60 - 40 Any

1.75 35 60 - 30 1, 4 or 5

2.0 40 60 - 30 Any

Turning 20 80 20 80 -

fig.8

fig.7

fig.9

fig.6

4.1.4. Connect the lathe to the mains supply.

4.1.5. Move the forward/reverse switch (fig.3.B) to Forward and then release the emergency stop switch (fig.3.C) by pushing the red cover

up in the direction of the arrow.

4.1.6 Move the chuck guard (see fig.1.1) down over the chuck. NOTE: The lathe will not start if the chuck guard is left in the up position.

4.1.7. Switch on the lathe by slowly turning the speed control (fig.3.A) clockwise.

4.1.8. For this initial start-up run the lathe for about five minutes, gradually increasing the speed up to its maximum. Run at maximum for a

further two minutes.

4.1.9. Switch off the lathe by turning the speed control (fig.3.A) anti-clockwise to zero and then moving the forward/reverse switch (fig.3.B)

to Off. Disconnect from the mains supply.

4.1.10. Check that nothing on the lathe has worked loose and that the mounting bolts, if used, are secure.

4.1.11. Repeat the above running and checking but with the high/low range lever in the High position.

4.2. Headstock

The headstock spindle, which is belt driven, has a flange with mounting holes

for chuck etc. and a number 3 Morse taper (internal) for a spindle centre

(see Accessories Section) .

4.3. Tailstock

The tailstock spindle has a number 2 Morse taper (internal) for a centre or

chuck. A plain centre is provided. See Accessories Section for the rolling

centre and tailstock chuck. The spindle is positioned using the feed handle (fig.1.3)

and then locked with the locking handle (fig.1.2).

The tailstock base may be moved along the lathe bed as necessary and

locked in position by the clamping nut (fig.1.4).

4.4. Tool Rest

Up to four tools can be mounted on the tool rest. The rest can be rotated, in

90° steps, by slackening the locking handle (fig.6.A), and slightly lifting the

rest. Always ensure that the locking handle and tool clamp screws (fig.6.B)

are tight before starting to cut.

The tool rest is mounted on the compound slide, which in turn is mounted on the cross slide. The compound slide can be rotated ±45°

on the cross slide to permit bevel and taper cutting. To rotate the compound slide, wind the tool rest fully to the right to reveal the two

clamp screws (fig.6.C). Loosen the clamp screws, rotate the slide to the required angle and then tighten the clamp screws.

4.5. Chuck

The chuck is supplied with internal jaws fitted and a set of external jaws. To remove and fit jaws proceed as follows:

Using the chuck key, fully wind out the fitted jaws, at which point they can be pulled from the chuck.

The thread segments on the jaws are staggered and therefore the jaws are numbered 1 to 3 and must be fitted in this sequence, in an

anti-clockwise direction (facing the chuck).

Turn the chuck key anti-clockwise while watching the chuck thread in one of the jaw slots. When the end of the thread has just cleared

the slot stop turning the key and insert jaw 1 into this slot. Insert the other two jaws in the other slots in sequence. Hold them under light

pressure whilst turning the key clockwise until they are picked up by the thread and start to move inwards.

Check that the three jaws come together correctly at the centre of the chuck. If not, repeat the procedure.

 WARNING! Before starting the lathe always confirm that nothing will contact the chuck by rotating the chuck by hand with the

tool rest as far to the left as it will be during the turning operation. Make sure that the chuck guard is in place, as shown in fig.1.1.

4.6. Turning

4.6.1. Mount the cutting tool in the tool rest such that the tip of the tool is level with, or just below, the lathe centre line. Check this by aligning

the tool tip with the point of the tailstock. The tool tip must not be above the centre line. The height of the tool tip may be adjusted by

shimming or grinding the tool.

4.6.2. Mount the workpiece in the chuck and if necessary, support the other end with the tailstock. Steady and Follow Rests are also available,

see Accessories Section.

4.6.3. Set the speed range, forward/reverse control and autofeed lever to suit the job.

4.6.4. Start the lathe by slowly turning the speed control clockwise until the required

turning speed is reached.

4.7. Turning with auto feed

4.7.1. Proceed as in 4.6. but in 4.6.3. also set the lead screw lever (fig.4.B) to Forward.

4.7.2. Position the tool just to the right of the end of the workpiece, start the lathe and

adjust the speed control knob to achieve the desired turning speed.

4.7.3. Push down the auto feed lever (fig.5.A) to engage the lead screw. The tool

will now move to the left and begin cutting.

4.7.4. Be ready to disengage the leadscrew when the tool reaches the end of the cut.

DO NOT allow the tool to over-travel and come into contact with the chuck.

Always be prepared to hit the emergency stop button if the leadscrew cannot

be disengaged.

Original Language Version SM3002.V2 Issue: 4 - 13/02/12

4.8. Screw cutting

Similar to turning with auto feed except that the feed rate is very much faster, demanding increased care from the operator.

4.8.1. Select the required leadscrew gear train from the chart (fig.7).

4.8.2. Undo the headstock end cover (fig.1.7) retaining screws and remove the cover.

4.8.3. Undo the three gear retaining screws (fig.8.1, 2 & 3), using the chuck key to hold the chuck (and therefore the gear train) if necessary.

Slacken the adjuster nut (fig.8.4).

4.8.4. Replace the existing gears with those required, in the positions shown in fig.9, taking care to retain the drive keys in each shaft.

Note that where only gears A, B and D are specified, spacer E is fitted after gear D (fig.9.1) - D then meshes with B. If a gear C is

specified then note that the gear D shaft spacer E must go on the shaft before the gear, which will then mesh with gear C (fig.9.2).

4.8.5. Adjust gear B, or gears B and C, so that the train meshes with minimum backlash but without being tight.

4.8.6. Tighten adjuster nut (fig.7.4) and refit the end cover. DO NOT operate the lathe without the end cover fitted.

4.8.7. Mount the workpiece in the lathe with the left hand end of the intended thread as far from the chuck as possible.

4.8.8. Ensure that the automatic feed is disengaged (fig.5.A) and that the leadscrew lever (fig.4.B)

is set to Forward.

4.8.9. With the tool positioned for the first cut, switch on the lathe and set to the appropriate speed.

Note: In order that the second and subsequent cuts start at the same place as the first cut it is vitally

important that the indicator dial (fig.10) is used, as follows, when starting each cut.

4.8.10. From the chart (fig.7) read the dial number(s) relating to the thread to be cut. If there is a

choice, select a specific number.

4.8.11. Engage the automatic feed as your selected number on the rotating dial passes the datum line.

4.8.12. When the tool reaches the end of the thread, disengage the automatic feed but DO NOT switch

off the lathe.

4.8.13. Reposition the tool for the second cut and engage the automatic feed again as your selected

number on the rotating dial passes the datum line. Repeat until the thread is finished.

fig.10

 WARNING! Ensure that the lathe is unplugged from the power supply before attempting any maintenance.

5.1. Lubricate the leadscrew bearings before each use (remove the end cover to access the left-hand bearing).

Lubricate the leadscrew thread before each use.

Lubricate the cross slide before each use (oil hole between hex. socket screws).

5.2. Clean the machine after each use and oil all machined surfaces.

5.3. The motor brushes may be inspected/replaced via screw caps which are accessed through holes, one in the front and one in the rear

of the headstock base.

5.4. If any play becomes apparent in either of the slides adjust as follows:

a) Loosen the lock nuts of the three gib strip adjusting screws (fig.6.D shows the screws for the compound slide. Those for the cross

slide are on the right-hand side of the slide).

b) Lightly tighten all three screws equally and check that the slide will not move with normal effort on the handle.

c) Back-off each screw by 1/4 turn and tighten the lock nuts.

d) Check that there is no play and that the slide moves smoothly.

e) If further adjustment is required, tighten or loosen the three screws as necessary by 1/8th of a turn only and re-check.

5. MAINTENANCE

NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.