YANGZHOU SUPER MACHINE TOOL CD6240 User manual

1
INSTRUCTION MANUAL
AND PARTS LIST
LATHE
MODEL: CD6240
MADE IN: YANGZHOU SUPER MACHINE TOOL CO.,LTD.
ADDRESS: No.198 HEYE WEST ROAD,YANGZHOU,CHINA
04/03/2020
Instructions Manual for CL-38 (L190)
1

2
CONTENTS
1. Guideline for Safety Operation……………………………………………4
1-1 Safety Points for Attention ………………………………………………… 4
1-2 Danger of Operation ………………………………………………………5
1-3 General Safe Rules for Operator of the Lathe……………………………7
1-4 Protection of the Chuck ……………………………………………………11
1-5 The Use of Emery Cloth in Metal Processing Can Cause Danger … ……..12
1-6 Safety devices………………………………………………………………14
2. Level of Noise…………………………………………………………………………18
3. Specification …………………………………………………………………19
4. Lifting……………………………………………………………………………20
5. Cleaning………………………………………………………………………21
6. Installing………………………………………………………………………21
7. Lathe Alignment Part.1……………………………………………………22
8. Lathe Alignment Part.2……………………………………………………23
9. Slide Ways Attention………………………………………………………24
10.Cross-Slide Nut………………………………………………………………24
11.Electrical Controls…………………………………………………………25
12.Speed Controls………………………………………………………………26
13.Threading Dial Indicator…………………………………………………27
14.Chucks and Chucks Mounting…………………………………………28
15.Electric Circuit Control……………………………………………………30
15.1 Wiring Diagram..........…………………….................…………..….….30
15.2 Electric Board Diagram..............................................................31
15.3 Electric Listing Component..............................................................................32
16.Bed Assembly………………………………………………………………33
17.Change Gear …………………………………………………………………38
18.Headstock Assembly………………………………………………………40
19.Gear Box Control……………………………………………………………52
20.Apron…………………………………………………………………………59
04/03/2020
Instructions Manual for CL-38 (L190)
2

3
21.Saddle…………………………………………………………………………66
22.Lubrication……………………………………………………………………71
23.Tailstock Assembly…………………………………………………………73
24.Chuck Guard Cover………………………………………………………76
25.Follow Rest……………………………………………………………………78
26.Steady Rest ……………………………………………………………………80
27.Lead Screw Guard…………………………………………………………82
28.Chip Protection………………………………………………………………83
04/03/2020
Instructions Manual for CL-38 (L190)
3

4
.1. Guideline for Safety Operation
The lathe is a high speed and powerful machine and can cause danger
if operate it improperly.
Before operating the lathe please read the following guidelines of
safety operation. Take care and observe to make the lathe be under
normal operation environment so as to avoid danger.
The lathe is in accordance with GB15760-1995 <General Technical
Condition of Safety Protection of Metal Cutting Machine> issued by the
state.
The manual covers information and hints necessary for proper and safe
operation of the lathe.
It is required the operator of the lathe should accept suitable technical
training before operating the machine, own skills to operate it and hold
the certificate of operation; or he should be trained under the close
supervision of somebody who can skillfully operate the machine.
The lathe should be operated under the environmental temperature of
+5°C - +40°C; the elevation up to 1000 m; the relative humidity of 50%
when ambient temperature is +40°C or higher relative humidity if
ambient temperature is lower.
The manual also covers related information for those who owns
necessary skills or appointed persons to make suitable maintenance upon
the machine.
1-1 Safety Points forAttention
1. Keep the lathe and the working area clean and in good order.
2. All guard devices and cover plates should be on the place; the side
cover should be closed.
3. Do not place any objects in the processing area of the lathe as they
may bump with rotating or moving parts.
4. Do not contact or leap over moving or rotating parts of the lathe.
04/03/2020
Instructions Manual for CL-38 (L190)
4

5
5. Before starting the lathe, you should understand how to stop it.
6. The lathe cannot be operated under overload.
7. Stop running of the lathe immediately in case any accident occurs.
8. When mounting the chuck or other attachment on the spindle, switch
off power supply of the lathe to prevent rotation of the spindle.
9. Do not mount the jigger if it is not checked of confirmed to be
compatible with the lathe.
10. Check the center you used if its load capacity can meet with
requirement.
11. Switch off power supply before leaving the lathe.
12. The maximum weight of the workpiece on the lathe is 500 kg.
13. The chuck should be properly and firmly mounted on the spindle of
the lathe.
14. Take care that the workpiece should be gripped firmly and the
speed of the spindle cannot exceed the safe speed of the chuck.
15. As it is possible to contact with human body, especially when the
material with small diameter is used, it is not allowed in any case that the
rod material cannot extend out the end of the spindle of the headstock
which has no special guard and relative support.
16. There is the label of speed limit for the chuck and that no speed
change is allowed in operation at the lower right corner of the headstock,
the electric warning board at the electric cabinet (box) and that no touch
on the workpiece (or chuck) when it is rotating on the guard of the chuck
to remind you to take care.
1-2 Danger of Operation
When operating the lathe you should fully understand the danger of
following operations:
1) Cutting Fluid
The cutting fluid is hazardous to human body. To contact the cutting
04/03/2020
Instructions Manual for CL-38 (L190)
5

6
fluid continuously especially the original fluid, it can cause the skin
allergic or ill if seriously, even the emulsion can also cause the same.
Therefore following precautions should be taken:
a. Avoid any unnecessary contact.
b. Put on the protective clothes.
c. Adopt guard shield or plate.
d. Do not wear oily or dirt clothes.
e. Clean all parts of the body where the cutting fluid is contacted after
work.
f. Do not mix different cutting fluids.
g. Replace the cutting fluid regularly.
h. Correctly treat the cutting fluid.
2) Safe Operation of the Chuck of the Lathe
All jiggers of work pieces should have clear labels of the maximum
safe speed and the speed of the spindle can never exceed it. It should
point out that the maximum safe speed on the label is supposed under
ideal work condition and lower speed of the spindle should be selected in
following cases:
a. Adopt the chuck to jig the workpiece under noisy work condition.
b. If the chuck is surely damaged, it is dangerous to operate under high
speed, especially when the chuck of grey pig iron is used it shall break if
it is something damaged.
c. If no griping force is known before jigging.
d. All factors such as strength of the workpiece to be jigged, balance of
the jigging faces and the workpiece etc. can largely affect the maximum
safe speed.
When the workpiece is rotation, it may not be jigged firmly due to the
role of centrifugal force and following factors may be involved:
a. The speed is too high.
04/03/2020
Instructions Manual for CL-38 (L190)
6

7
b. The weight and type of the claws are off standard.
c. The working radius of the claw is unsuitable.
d. The claw ahs bad lubrication.
e. It is unbalanced.
f. The dynamic factor is not considered in the jigging force.
g. Too large cutting force.
h. Is the workpiece jigged internally or externally?
These factors should be seriously considered as they can cause
different influence in different purposes. The manufacturer cannot
provide concrete data for general use as they are beyond the range
controlled by the manufacturer of the machine.
1-3 General Safe Rules for Operator of the Lathe
1. When jigging the workpiece, it cannot have oil or grease;
All parts should be jigged firmly;
Do not intend to jig the workpiece which is unsuitable or hardly to jig
well;
Do not jig the workpiece exceeding the weight allowed by the lathe;
Master suitable hoisting method when the workpiece is hoisted.
2. Ensure to remove oil or grease on handy tools and operation
grippers;
Ensure the structures of handy tools and operation grippers are suitable
to touch safely by hand.
3. When operating the handy tool or the operation gripper, it should be
gripped firmly;
Select suitable position to grasp on the handy tool or the operation
gripper;
You cannot grasp the handy tool or the operation gripper on unsuitable
position;
You cannot operate with excessive force.
04/03/2020
Instructions Manual for CL-38 (L190)
7

8
4. Grasp the handy tool or the operation grippe on recommended
positions.
5. Do not allow to leave other handy tool or operation gripper on the
chuck.
6. Do not allow to use broken, damaged or defected tool.
7. Ensure the workpiece is jigged firmly on the chuck or other jiggers.
8. Take special care of irregular workpiece.
9. Take care of large flashes and burrs on the workpiece.
10. Always take care to select correct tool in work.
11. It is not allowed to leave other unfixed handy tool or operation
gripper on the chuck.
12. Do not allow to use the tool without the handle.
13. Always adopt the chuck, the follow rest and the center to support
the workpiece.
14. The workpiece should have correct position in the hexagon hole
and the groove of the screwdriver.
15. Take care that the locking screw should be tightened.
16. Do not make preparation work in a hurry.
17. Never use the substitute tool if no suitable tool is available or
prepared in the workshop.
18. Do not allow to move away the guard plate or to open the
protection door when the lathe is switched on.
19. Do not let your hands or body be within the working area of
moving parts.
Take care to move parts of the lathe which could drop down.
Take care of relative position between the hand or the body and the
lathe.
Take care of the tool to be grasped and other parts inserted in the chuck
or the workpiece.
Do not let your hands or body be on the place where they could be hurt
04/03/2020
Instructions Manual for CL-38 (L190)
8

9
by the chuck or the workpiece.
20. Take care not to push the handle, to operate the clutch or to witch
on power supply to cause accident.
21. Master every function and all kinds of operation methods.
22. Never put your hands on the chuck or the workpiece to stop
rotation of the spindle.
23. For the lathe driven by the clutch, in case the clutch is disengaged,
the spindle should be stopped running otherwise the clutch or the brake
device should be adjusted.
24. When the lathe is not in use, ensure to switch off power supply of
the lathe.
25. Stop the rotation of the chuck before replacing the new workpiece.
26. Always take care to check if driving of the chuck, the belt pulley
and driving parts are loose.
27. When the handle of the chuck is in the chuck, never start the
spindle.
28. Do not operate the laths if the attention is not concentrated in order
to avoid accident.
29. When preparing to make other operation of the lathe such as the
tailstock, take care to avoid danger such as bumping or dropping.
30. Take care of guard cover of the chuck and other covers which
cannot be loosened.
31. Put on the safety cap to operate the lathe if the operator has long
hair to avoid danger due to hair is wounded by rotating parts of the
machine.
32. Take special care to make operation if you are closing to rotating
part of the machine.
33. Always pay attention to filing and deburring:
Take special care when the file or the deburring tool is closing to the
chuck;
04/03/2020
Instructions Manual for CL-38 (L190)
9

10
The file or the deburring tool could bump the chuck.
34. For the lathe driven by the clutch, take care that the clutch should
be at the position the lathe is stopped when making measurement.
35. Take care of rotating and stopping positions of the spindle when
hand is on the handle of the clutch.
36. Ensure the spindle of the lathe should be at the stop position when
measuring the workpiece jigged on the chuck.
37. When the measuring meter is used on the lathe, ensure the motor is
at the stop status.
38. Wear protective gears met with safe standard before making
operation on the lathe;
It is not allowed if taking off protective gears in a short period of time
before making operation on the lathe;
Wear protective gears properly.
39. Take cars of cuttings flying out from the lathe.
40. Select suitable guard plate on the operation position.
41. Never leap over or go around the chuck or the workpiece to make
adjustment when they are in running status;
Never leap over or go around the chuck or the workpiece to take
something;
Take care of the place the workpiece is put when making adjustment of
the lathe or the workpiece;
Never leap over or go around the chuck or the workpiece to move the
tool/lathe to other position;
Never leap over or go around the chuck or the workpiece to tighten
parts on the lathe;
Never leap over or go around the chuck or the workpiece to remove
iron chips.
42. Master suitable method to load, and never apply force from
unsuitable position.
04/03/2020
Instructions Manual for CL-38 (L190)
10

11
43. Never mount the workpiece too large or heavy toward the lathe.
44. Never mount the workpiece too large or heavy toward the operator.
45. Use necessary tools to treat the workpiece.
46. Never apply excessive force on the attachment or the operation
lever.
47. Take care to jig the workpiece firmly.
48. Tighten all claws, nuts, screws and fasteners.
49. Always take care to use correct equipment.
50. Never make cutting beyond the ability of the lathe.
51. Do not apply excessive force to polish or to deburr.
52. Always take care to adopt suitable tool to deburr. Do not deburr in a
hurry and take care of burrs on the chuck and the workpiece.
53. Switch off power supply to stop all movements of the lathe before
replacing the exchange gears.
54. Take care if the chuck/parts could drop down when the lathe is in
operation.
1-4 Protection of the Chuck
The lathe is equipped with the guard of the chuck (option), which is
suitable for the standard chuck.
In case the chuck guard is equipped on the lathe, it should be in a
closed status before the spindle is running.
1) When the machine is equipped with larger chuck, the chuck guard
should be replaced with one which has corresponding diameter with that
of the chuck.
It is suggested that claws cannot extend out the outer diameter of the
chuck in order to avoid bump with the chuck guard. For the sake of safe
operation, always take care not to extend claws out of the outer diameter
of the chuck.
2) When the face chuck is used, the chuck guard should be removed. If
04/03/2020
Instructions Manual for CL-38 (L190)
11

12
it is indeed required by customer, the special chuck guard can be provided
but it should be confirmed that only the face chuck is used and any case
should be responsible by customer himself.
1-5 The Use of Emery Cloth in Metal Processing Can Cause Danger
In all accidents occurred on the lathe, most are from the use of emery
cloth to cause breakage of fingers, or even to amputate occasionally.
When workpieces with different shapes are rotating on the lathe, if
using emery cloth to deburr, to polish or to process finished sizes, it can
cause the accident when winding emery cloth on the workpiece to be
ground by two hands. If winding the emery cloth on the finger or to make
rough grinding, the finger could be seized firmly to cause serious injury.
Precautions
The operator should have certain recognition and knowledge on the
necessity to treat part by emery cloth on the lathe.
It is not needed to process by emery cloth in following cases:
If the requirement of the surface roughness is not so high;
Make processing by turning or on special polisher or grinding machine,
the finished sizes and surface roughness can be achieved well.
If technological rule defines that the workpiece should be ground by
04/03/2020
Instructions Manual for CL-38 (L190)
12

13
emery cloth, then the emery cloth should be used in following cases:
a. Nail the emery cloth on a quality wood board to grind;
b. The emery cloth is fixed on and jigged by the tool holder to grind.
c. The “Robust Grinder” consists of two pieces of jointed wood board
and the emery cloth to make grinding and the workpiece to be polished
can go through its hole.
d. The polish is made by the wire brush stuck with abrasive material.
Apply force at the both ends of the emery cloth to pull it upward.
Never pull it loosely or wind it on your finger or on the workpiece.
04/03/2020
Instructions Manual for CL-38 (L190)
13

14
When the end of the workpiece is polished, only a short piece of the
emery cloth shall be used as it cannot be wound.
When polish by the emery cloth is made, never operate by wearing
gloves.
1-6 Safety devices
Operate the lathe only with properly functioning safety devices.
Stop the lathe immediately if there is a failure in the safety device or if
it is not functioning for some reason.
It is your responsibility!
If the safety device has been activated or has failed, the lathe must only
be operated again when
•the cause of the failure has been removed,
•you have made sure that there is no existing danger for persons or
objects.
WARNING!
If you bypass, remove or override a safety device in any other way,
you are endangering yourself and other persons working on the lathe.
The possible consequences are the following
•injuries due to components or parts of components flying off at
high speed,
•contact with rotating parts,
•fatal electrocution,
•pulling-in of clothes.
The lathe includes the following safety devices:
•a lockable main switch,
•an EMERGENCY-STOP button,
•a protective cover on the headstock with position switch,
•a lathe chuck protection with position switch,
•a recoil spring as protective cover on the guide spindle, the coil
04/03/2020
Instructions Manual for CL-38 (L190)
14

15
spring prevents the pulling-in of clothes into the guide spindle,
•chip protection,
·securing screw
•an overload clutch on the feed shaft,
•safety screws for the Camlock bolts on the workpiece holder.
a. Lockable main switch
In the position "0", the lockable main switch can be secured against
accidental or non-authorized switching-on by means of a padlock.
When the main switch is switched off, the current supply is being
interrupted.
Except for the areas marked by the ideogram in the margin. In these
areas, there might be voltage, even if the main switch is being switched
off.
WARNING!
Dangerous voltage exists even if the main switch is switched off.
In the areas marked by the ideogram in the margin, there might be
voltage, even if the main switch is switched off.
b. EMERGENCY-STOPbutton
The EMERGENCY-STOP button switches the lathe off.
After actuating the switch, turn it to the right, in order to restart the
lathe.
main switch
EMERGENCY-
STOP button
04/03/2020
Instructions Manual for CL-38 (L190)
15

16
c. Protective cover on the headstock
The headstock of the lathe is provided with a protective cover and a
position switch.
The lathe only starts when the protective cover is mounted.
WARNING!
Only remove the protective cover when the main switch of the
lathe is turned off and secured by a padlock.
d. Lathe chuck protection with position switch
The lathe is provided with a lathe chuck protection. The lathe can only
be switched on if the lathe chuck protection is closed.
positions switch
Lathe chuck protection
04/03/2020
Instructions Manual for CL-38 (L190)
16

17
e. Chip protection
The lathe is provided with a protective cover for the tool cutting chip.
f. securing screw
Tighten the securing screw at the end of the lathe bed in order to
prevent the tailstock from unintentional drawing-out of the lathe bed.
positions switch
Chip protection closed Chip protection opened
Integrated position switch
04/03/2020
Instructions Manual for CL-38 (L190)
17

18
Safety check
Check the lathe at least once per shift. Inform the person responsible
immediately of any damage, defect or change in the operating function.
Check all safety devices
•at the beginning of each shift (with the machine stopped),
•once a week (with the machine in operation),
•after every maintenance and repair work.
Check that the prohibition, warning and information labels as well as
the markings on the lathe
•are legible (clean them, if necessary),
•are complete.
2. Level of Noise
According to GB/T16769-1997 <Measurement Method of
Sound-Pressure-Level of Metal Cutting Machine>, measure the noise at
six positions being one meter far from the lathe. The maximum noise
should be less than 85dB（A）.
Note: The measurement should be made at the spindle with standard
chuck at the maximum speed.
04/03/2020
Instructions Manual for CL-38 (L190)
18

19
3. Specification
Capacity
Swing Over Bed 360mm(14") or 410mm(16")
Swing Over Cross Slide 215mm(81/2") or 255mm(10")
Swing In Gap Diameter×Width 540(211/4") or 580(23")×190(71/2")
Height of Center 185mm(71/2") or 205mm(8")
Distance Between Centers 1000mm(40")/1500 mm
Width of Bed 250mm(10")
Cutting Tool Max Section 20×20mm(3/4"×3/4")
Total Travel of Cross Slide 210mm(81/2")
Total Travel of Top Slide 140mm(51/2")
Headstock
Spindle Bore 52mm(2")
Spindle Nose D1-6
Spindle Morse Taper in Bore M.T.No. 6
Spindle Speeds Number 16
Spindle Speeds Range 45-1800R.P.M
Thread & Feeds
Leadscrew Diameter & Thread 28mm×6mm or 4T.P.I
Threads Imperial Pitches 2-72T.P.I(45Nos)
Threads Metric Pitches 0.2-14mm(39Nos)
Longitudinal Feeds Imperial 0.002"-0.067"/Rev (17Nos)
Longitudinal Feeds Metric 0.05-1.7mm/Rev (17Nos)
Cross Feeds Imperial 0.001"-0.0335"/Rev (17Nos)
Cross Feeds Metric 0.025-0.85mm/Rev (17Nos)
Range of Module Pitches 0.3-3.5MP(18Nos)
Range of Diametral Pitches 8-44DP(21Nos)
Tailstock
Total Travel of Tailstock Quill 120mm(43/4")
Tailstock Quill Diameter 50mm(2")
Taper in Tailstock Quill M.T.No.4
Motors
Spindle Drive Motor 4P/8P, 3PH 3.3/2.2kw or 4.5/3kw
Coolant Pump Motor 4P, 3PH 90W
Weight & Measures
Machine Space Requires (L×W×H) 194（244）cm×85cm×130cm or132cm
Packing Case Dimensions (L×W×H) 206 (81")×90 (357/16")×164cm(649/16")
Net Weight 1300kg or 1350kg/1550kg or 1600kg
Gross Weight 1500kg or 1555kg/1750kg or 1755kg
04/03/2020
Instructions Manual for CL-38 (L190)
19

20
4. Lifting
Use a sling-chain to sling the lathe as in fig position the saddle
and tailstock along the bed to obtain balance.
Important: The sling-chain should not touch the leadscrew or
Feed-shaft to avoid damage.
Unloading of the machine. When the machine is unloaded from the car
or to be moved, please proceed with
following steps (Fig.1)
1. Preparing two round sticks (long
approx.800mm dia 35mm) insert into
the preserved holes on lathe bed. Then
lift up with applying wires on both end
of the stick.
Lifting the machine by a crane.
3. Before lifting adjust the position
of Lathe Apron and Tailstock to
maintain the balance of machine.
4. When the machine was shifted to its destination, always handle with
care to put it down. Don’t let go of it to hit the ground or it will affect the
accuracy of the machine
Note: Machine weight can be seen in Specification Table.
5. For the adjustment of electric control, keep the distance between
machines and wall not less than 600mm.
Fig.1
04/03/2020
Instructions Manual for CL-38 (L190)
20