Jesco PRINCE, Instruction & Parts Manual

Page 1: ...S MANUAL Original instructions JESCO MACHINERY LTD P O BOX 14 9 TAIPING TAICHUNG TAIWAN R O C TEL 886 4 22702676 FAX 886 4 22706295 E MAIL jesco1 ms22 hinet net Web Site www jesco com tw File No Rev Date Editor Approval Comments JCET 0001 01 2009 10 Ken ...

Page 2: ...r operator at any time Make sure that only authorized personnel work on the machine Just well trained technicians can operate the hydraulic pneumatic electrical control system Environmental protection Local environmental safety regulations must be observed when handing dangerous substances Observe respective safety regulation for products when using oils grease and other chemical substances Specia...

Page 3: ...t allowed to be used on this machine The machine can cut the material like cast iron steel copper aluminum doing the turning boring drilling and tapping etc jobs In addition it is informed in operation manual for maintenance setting and cleaning etc NOTE The machine is NOT allowed to work with flammable metal working fluids or materials as aluminum or magnesium which can cause fire and explosion o...

Page 4: ... TRUCK CAPACITY 9 OPERATING SAFETY PRECAUTIONS 11 NOISE LEVEL 12 ACCIDENTS AT LATHES BY USING EMERY CLOTH 13 OPERATION 15 FOUNDATION PLAN 16 ILLUSTRATION OF HAZARD REGION 19 ILLUSTRATION OF SAFETY DEVICE POSITION 20 SAFTY OF MACHINE TOOL GUARDS 20 CLEANING OR LEVELLING LATHE 22 CHUCKSANDCHUCKMOUNTING 25 CHUCK JAW DETAIL 26 SPEEDCONTROLS Standardlathes 28 VARISPEED LATHES 29 QUICK CHANGE GEAR BOX 3...

Page 5: ...ere Free from excessive dust acid fume corrosive gases and salt f Avoid exposing to direct sunlight or heat rays g Avoid exposing to vibration environmental h Have to connect to the factory grounding system correctly i Away from electric magnetic interference source sites such welding discharge machine ELECTRICALLY SUPPLY The following AC supply information a Voltage Steady state voltage 0 9 to 1 ...

Page 6: ... 2 7 0mm Inch Gearbox 32 4 56TPI Metric Gearbox 24 4 28TPI Number range of Imperial threads Universal Gearbox 36 4 72TPI Number range of Module threads Universal Gearbox 18 0 3 3 5mm Number range of DP threads Universal Gearbox 21 8 44 D P Range of longitudinal feeds 0 038 0 254mm 0 0015 0 01 Opt 0 02 0 52 mm 0 0008 0 0205 Range of cross feeds 0 012 0 090mm 0 0005 0 0035 Opt 0 006 0 170 mm 0 00023...

Page 7: ...880 Major 1800 2000 3254 1086 1325 Major 2040 Major 2000 1000 2237 1086 1349 Major 2060 Major 2000 1500 2745 1086 1349 Major 2080 Major 2000 2000 3254 1086 1349 Major 2240 Major 2200 1000 2237 1086 1375 Major 2260 Major 2200 1500 2745 1086 1375 Major 2280 Major 2200 2000 3254 1086 1375 General 2660 General 2600 1500 3900 2000 1700 General 2680 General 2600 2000 4425 2000 1955 General 3060 General ...

Page 8: ...160 General 2600 4000 6425 2000 1955 General 30120 General 3000 3000 5425 2000 1955 General 30160 General 3000 4000 6425 2000 1955 TOOL INFORMATION MODEL Tool shank mm Tailstock drill A mm Tailstock drill B mm Tailstock drill Max Weight kg PRINCE 20 18 100 3 5 STUDTURN 20 18 100 3 5 CHAMPION 25 24 120 5 MAJOR 25 24 120 7 GENERAL 25 31 150 10 TRAINER 20 18 100 3 5 KNIGHT 25 24 120 5 A B C ...

Page 9: ... CASE 1 Locate the wooden case on a flat and sufficient area for easy working 2 Clean the area and space 3 Wear gloves and suitable safety equipments 4 Use the claw hammer or nail extractor to pull out nails especially the nails on sheet bands at four top corners 5 0pen the top cover first 6 Pull down the four side covers carefully WARNING Be careful of sharp nails 7 Remove any broken wood pieces ...

Page 10: ...0 1250 8 2450 1800 1850 12 2450 1800 2000 Please pay attention to transport and lift this high precision machine for avoiding any strong extrusions or collisions The lifting capacity of forklift truck must be sufficient for the machine Table shows the forklift truck capacity ...

Page 11: ... drawing below 4 Carefully and slowly lift the lathe clear of the wooden base or ground and if necessary reposition the carriage or tailstock to achieve a better balance before lifting any higher or further 5 If you reposition the carriage or tailstock make sure you re tighten and lock them in place 6 After a full load is on the main hook check to make sure that the lifting hook swivels freely and...

Page 12: ...ACTURER 16 DISCONNECT LATHE FROM POWER SOURCE BEFORE PERFORMING ANY MAINTANENCE OR CHANGING TOOLING 17 ISOLATE LATHE WHEN LEAVING IT UNATTENDED 18 THE MACHINE IS NOT ALLOWED TO WORK WITH FLAMMABLE METAL WORKING FLUIDS OR MATERIALS AS ALUMINUM OR MAGNESIUM WHICH CAN CAUSE FIRE AND EXPLOSION OR NOXIOUS DUST 19 DON T WEAR GLOVES DURING OPERATION ONLY WHEN LOADING AND UNLOADING WORKPIECE COULD WEAR GL...

Page 13: ...there is a correlation between the emission and exposure levels this cannot be used reliably to determine whether or not further precautions are required Factors that influence the actual level of exposure of the workforce include characteristics of the workroom the other sources of noise etc i e the number of machines and other adjacent processes Also the permissible exposure level can vary from ...

Page 14: ...eing linished If the Cloth is wrapped around the fingers and or becomes snagged on the component while it is tightly gripped then a serious injury is the likely result PRECAUTIONS Emery cloth should NEVER be used at CNC lathes Employers should assess the need to use emery cloth on components in a lathe Such operations may not be necessary if a the finish being sought is only cosmetic For such fini...

Page 15: ... c d Or hand held abrasive impregnated wire brushes WARNING Gloves should never be worn when polishing is being carried out Where none of the above methods is reasonably practicable and it is necessary to use Emery Cloth for polishing the outside diameters of components the Emery Cloth should be used in long strips with one end passed beneath the component Force should be applied by pulling both e...

Page 16: ...EADSCREW 15 HALF NUT LEVER 16 FEED ROD 17 CROSS LONGITUDINAL FEED KNOB 18 FEED ENGAGEMENT KNOB 19 CARRIAGE HANDWHEEL 20 CROSS SLIDE HANDWHEEL 21 CHIP PAN 22 QUICK CHANGE GEAR BOX 23 GEAR SHIFT KNOB 24 FEED OR THREAD CHANGE KNOB 25 QUADRANT COVER 26 FEEDING DIRECTION SELECT KNOB 27 ELECTRICAL CONTROL PANEL 28 FEED THREAD SELECTOR KNOB 29 SPINDLE SPEED SELECTOR 30 FOR OFF REV CONTROL SHAFT 31 SPINDL...

Page 17: ...16 FOUNDATION PLAN 300 40X4HOLES A 350 500 570 ...

Page 18: ...17 ANCHOR BOLT DIAGRAM ...

Page 19: ...18 CONNECTION OF EXTRACTION SYSTEM 18 To Extraction System 18 ...

Page 20: ...N Arrow shows the directions of movement in the danger area SPINDLE SADDLE C R O S S S L I D E Item Name 1 Chip Guard moveable guard 2 Chuck Guard 3 Heanend Guard 4 Rear Guard 5 The area between the leadscrew and second rod 1 2 3 4 5 ...

Page 21: ...chine can t be started if door is opened SAFTY OF MACHINE TOOL GUARDS NOTE CHUCK GUARD AND CHIP GUARD ARE ABLE TO REDUCE MOST OF RISKS BUT UNAVAILABLE TO PREVENT 100 RISK Turning machine must now comply with the following European Safety Standard EN12840 Safety Manually Controlled Turning machines with or without automatic control The machine is supplied as standard with 3mm mild steel chuck guard...

Page 22: ... 4 22702676 FAX 886 4 22706295 E mail jesco1 ms22 hinet net http www jesco com tw JESCO CE nameplate 2 Electric shock Operate carefully 3 On the whipping hazard and stating that exposed stock bars shall be guarded 4 Coolant drain port 5 Please don t open it when operation 6 High speed Do not put hands near it when machine operation ...

Page 23: ...lowing sufficient area all round for easy working and maintenance see Foundation Plan The lathe may be used free standing or bolted to the foundation FREE STANDING Position lathe on foundation and adjust each of the eight ten mounting feet to take equal share of the load Then using a machinist s precision level on the bedways as in Fig 2 adjust the feet to level up machine Periodically at least ev...

Page 24: ...3HP motor as well as short from the power source Main motor rotation must be clockwise viewed from the pulley end Should motor run in wrong direction interchange any two of the three phase leads Appropriate wiring diagrams are included in this manual WARNING All electrical power connections must be provided by a qualified electrician Proper grounding and fused main disconnects are necessary Fig 3 ...

Page 25: ...he end gear cover to replenish the oil from both filler elbows F and to drain the oil from both drain plug D Fig 6 For the apron to replenish the oil from the oil cap on saddle and to drain the oil from drain plug at the bottom of apron To the slideways leadscrew feed rod and all the oilers located on saddle cross slide top slide tailstock and end bracket etc Apply an oil can to all the points sho...

Page 26: ... A reference mark should be made on each correctly fitted chuck or faceplate to coincide with the reference mark scribed on the spindle nose This will assist subsequent remounting DO NOT INTERCHANGE CHUCKS OR FACE PLATES BETWEEN LATHES WITHOUT CHECKING FOR CORRECT CAM LOCKING WARNING Chuck should be CE approval of EN 1550 the relevant required markings in it Take careful note of speed limitations ...

Page 27: ...gripping force due to centrifugal effect is a function of the product of top jaw mass and the distance to the jaws centre of mass about the chucks rotational axis Precautions should also be taken to ensure that projecting top jaws will not collide with tooling during the machining cycle Care should be exercised in machining workpieces whose length protrudes excessively beyond the chuck jaws As a g...

Page 28: ...bs button switches functions as bellows 1 The BLACK select knob A for coolant pump switch ON OFF 2 The WHITE pilot lamp B glows to show the main supply ON 3 The RED mushroom head button C to stop all the electrical supply 4 The GREEN push button D to press for spindle jogging 5 The BLACK select knob E for two speed motor High Low selection 6 The BLACK turning knob F for spindle speed control on Va...

Page 29: ...tation Return to netural position for spindle stop FOOTBRAKE A foot pedal located between machine base plinths operates the spindle brake and cut off the power to the drive motor After the foot brake is applied the lever A should be returned to the neutral position to re start the spindle rotation WARNING NEVER SHIFT SPEED CONTROL LEVERS B C AND FEED LEVERS D E ON THE HEADSTOCK WHILE THE SPINDLE I...

Page 30: ...es selection STOP THE SPINDLE first and then rotates the select lever B to engage HIGH or LOW speed range Rotate the select turning knob C on control panel to the minimum position by counter clockwise Then to operate the control lever A for spindle rotation and turning the select turning knob C clockwisely from minimum to the desire constant speed slowly The speed meter built on the top of the ele...

Page 31: ...speeds for threading turning and facing operations The range of feeds and threads there selection and the positions of the knobs for each feed or thread are shown on the machine chart According to requirement there are three types for Quick Change Gear Box One is Inch Gear Box Fig 12 second is Metric Gear Box Fig 13 Third is Universal Gear Box Fig 14 ...

Page 32: ...ntime ensure the end gear train engagement U V W X Y Z according to chart also FOR UNIVERSAL GEAR BOX OPTIONAL Both of INCH AND METRIC threads and feeds cutting available to obtain from the universal gear box directly According to chart Fig 17 and turn selectors correspond to chart for the desired threads or feeds cutting Also beware the end gear trains engagement and F W selectors on chart accord...

Page 33: ...ng dial is located on the right side of the apron It performs the important function of indicating the proper time to engage the half nut lever so that the tool will enter the same groove of the thread on each successive cut The dial is marked with lines numbered 1 2 3 4 and in between is lines with no numbers These are half lines and are called unnumbered lines The dial when engaged with the lead...

Page 34: ...d turning the toolpost for change then re tighten clamp lever TAILSTOCK The tailstock slide along the bedways and may be anchored in any position by press the clamp lever To slide the quill from rotating the tailstock handwheel the quill lock lever can lock the quill For small tapers the tailstock can be set over by loosening the clamp lever and both fixed screws under the front and the rear of th...

Page 35: ...eware to release four fixed screw of the headstock to the bed before adjustment and re tighten it after adjustment 2 SPINDLE BEARING ADJUSTMENT When we find the spindle bearings are too tight or loose open the rear bearing cover A and loose the set screw B on the spindle bearing thrust nut C and then adjust the thrust nut by loosing or fastening The proper adjustment is finished by fastening the s...

Page 36: ...iscover the leadscrew is in loose status you should first loose the external end nut A which are located on the sleeve of lead screw then tighten the internal nuts B to proper fit The correction work will be completed by refastening external end nuts 6 ADJUSTMENT OF HALF NUT When half nut has been worn out for long service and caused loose dismantle the apron body from carriage loose the screw A a...

Page 37: ...n adjustable screw A on the cross feed nut will be adjusted and fastened again 2 Loosen the external thrust nut which is located at the end of cross feed screw as shown on 8 2 thrust nut D to proper position The adjustment work will be completed by re tighten the external thrust nut 9 ADJUSTMENT OF CARRIAGE BACK CLAMP In order to keep leveling accurate the excess clearance between carriage and bed...

Page 38: ...e should be adjusted by two opposite adjusting screws A to move the tailstock to the centerline position Beware to loose two set screws B and clamp lever C between base and body before adjustment Complete the adjustment by re tighten two set screws B 12 ADJUSTMENT OF THE CLAMP HANDLE LEVER OF THE TAILSTOCK If the tailstock clamp is fixed to the bed unstable you should readjust the adjusting nut A ...

Page 39: ... oil in tank and switch on the pump for inspecting its function and leakage 3 Caution on operation A Temperature of bearing After half hour running to examine the main spindle bearing temperature by hand feeling with normal warm up B Abnormal noise and vibration To stop the lathe immediately for inspection and adjustment C Miss accuracy of products When the product is out of limit accuracy to stop...

Page 40: ...ve screws or nuts according to the instructions listed in the previous chapters 4 Check the leveling To examine the leveling by adjusting and tighten the leveling screws 5 Check the accuracy To examine and adjust if necessary the alignment clearance etc as the accuracy test record accordingly 6 Check the gears and bearings The abnormal noise may cause on worn gears and bearings if necessary replac...

Page 41: ...or gasket 5 Leakage from overflow on spindle Less oil flow to bearing or enlarge oil bearing housing return flow 1 Badly worn bearing Replace bearing 2 Lost levelling Recheck levelling tighten 3 Badly worn V belts Replace V belts 4 Loose belt tension Adjust belt tension 5 Badly worn gear Replace gear 6 Bent or sprung shaft Straighten or replace shaft 7 Pulley lossened Tighten pulley set screw 8 Cl...

Page 42: ...place or adjust the end gear Uneasy to cut thread 6 Bent leadscrew Straighten it 7 Incorrect threading tool and wrong Replace threading tool and reset it positioning 8 Incorrect engage the halfnut Engage the halfnut exactly 9 Threading dial indicator not properly Adjust the indicator engagement on engaging with leadscrew leadscrew 10 Too much infeed per cut or too fast Reduce the infeed per cut or...

Page 43: ...t 4 Foundation inadequate or motor feet uneven Stiffen mounting place or add shims under foot pad 1 Excess belt tension Adjust belt tension 2 Cooling fan failure Check the fan in proper work Overheat in motor 3 Badly worn on bearing 4 Short grease in bearing Replace bearing Replenish grease 5 Overload Reduce cutting speed or feed rate 6 Incorrect speed range running continuous Change speed range a...