CLAUSING COLCHESTER CLAUSING 15” GEARED HEAD CENTER LATHE INSTRUCTION AND SPARE PARTS MANUAL Clausing : pada CLAUSING INDUSTRIAL INC . KALAMAZO 1819 H PITCHER ST KALAMAZOO MlThis manual applies only to machine having the serial numer:shown; this is stamped on the front of the lathe bed at the tailstock end ani | MUST be quoted in all communications. Machine Serial Number: ‘ear of Manufacture: 2001INSTALLATION MACHINE SPECIFICATION Centres Tailstook. Height ‘195i (7.68") ‘Quill diameter (nominal) 73mm (28°) Admits between Travel 140mm (6.5") Morse taper No.5 MT. swing Set over 10mm (0.47) ‘Over bed (saddle wings) ‘400mm (16.7°) Over cross-slide 246mm (9.77) Leadserew In gap , ‘585: 23") Diameter samm (1.25% With in front of faceplate tes5mm (65°) Thread, rom pitch or 4.P., Spindle Threads é Bored to pass 4mm (2.426") Mette pltches 0.2-14mm (51) Nose Type 1-6" Camlock Importet T.P.t 2:58 (66) Morse taper in bush No.4 MT Module pitches 0.2-8.5 (20) Dlamatral pitches 8-56 (20) Spindle Speeds Selected in 4 ranges of 4 speeds in each range Feeds 2 35D Mettic (R10) Serles) 0.036 - 2.4mmv/rev 80 © 108 «140,490 260 950 470625 840 1120 1500 2000 Imporial (R10 Series) 0.0014 - 0.096in/rev Gross feeds = half longitudinal values (approx) ‘Quick change tooling Dickson No.2 E Motor (main) 5.5Kw (7.SHP) Holgtit of Machine Bed Floor to spindle centre 41070mm(42. Wisth of waye ‘st@mm (12.5%) Type of ways Vee and fat Overall Length 250mm (88.4") Cross-Stide Overall Wieth 100mm (43 Wiath and length 180mm (7") = 850mm (93.5") Travel 250mm 2.8") Overall Helght 00min (61:2") “Top Slide Weight 1800kg (8300 b) wath 100mm (4*) For other dimensions 608 fourdation plan Travel 490mm (6.1") 2 ‘Tool section 25x 26mm (1*x 1) Coolant Pump FlowINSTALLATION : NOISE LEVEL @ The maximum noise level at the oparators position (Fig.1) is within 85 dB(A) and the maximum mean noise level is within 85 dB(A), TRIUMPH GEARED HEAD CENTRE LATHE | “ bel | Fig.0 e@ NoTE: i ‘The operators position is postion 1 and the mean is taken from the readings at all 6 positions. | ‘The conditions of measurement are with the spindle running at top speed, with a standard chuck fitted, with no feed engagement, i ‘These measurements are in accordance with BS4813 : 1972CONTENTS OPERATING SAFETY. Machine Specification Noise Level INSTALLATION :- - Machine Weight And Lifting, Installation Cleaning Electric Supply Connections “Foundation Plan - (Chuck Mounting OPERATION = Lathe Safety Control Layout Speed Selection Thread and Feed Selection Thread Dial Indicators ‘Apron and Stide Controls Tallistock and Coolant Gap Piece Removal SERVICE AND MAINTENANCE:- Lathe Alignment End Gear Train and Driving Belt Leadserew Torque Limiting Devie’, Drive Clutches Caliper Brake Unit ‘Change Gear Shear Pin Slideways and Cross-Slide Nut Headstock, Gearbox, and Apron Lubrication Lubrication Chart ‘SPARE PARTS SECTION. ACCESSORIES. ELECTRICS, PAGE I-xil eearane " 12 13 4 15 16 7 18 19 19 20 24 22 22 23 24 INDEXOPERATING SAFETY HEALTH AND SAFETY GUIDANCE NOTES PLEASE READ CAREFULLY #f BEFORE OPERATION OF YOUR LATHEOPERATING SAFETY OPERATOR SAFETY ‘These Lathes are fast, powerful machines which can be dangerous if used under im- proper circumstances. Read the following Health and Safety Guidance Notes and observe before and during the use of the machine. HEALTH AND SAFETY AT WORK ACT 1974 (U.K. ONLY) In accordance with the requirements of the Health and Safety at Work eto. Act 1974 this. manual contains the necessary information to ensure that the machine tool can be oper- ‘ated properly and with safety. It is assumed that the operator has been properly trained, has the requisite skill and is authorised to operate the machine, or, # undergoing training, is undor the close supervision of a skilled and authorised person. Attention is drawn to the importance of compliance with the various statutory regulations which may be applicable, such as "The Protection of Eyes Regulations’. Itis further stressed that good housskeeping, common senso and the maintenance of good established work shop practice is essential, Adequate information is also provided to enable the machine to be properly serviced and ~ maintained by persons with the necessary skills and authority.OPERATING SAFETY OPERATING HAZARDS When using the machine be FULLY AWARE of the following operating hazards detalled undar the following instructions; a) ») METAL CUTTING FLUIDS Cancer of the skin may be produced by continuous contact with oil; particularly with straight cutting oils, but also with soluble oils: The following precautions should,be taken: . 1. Avoid unnecessary contact with cil 2. Wear Protective olothing. 3. Use protective shields and guards. 4, Dont wear oil soaked or contaminated clothing 5. After work thoroughly wash all parts of the body that have come into contact with olls, 6. - Avoid mixing different types of oils. 7. Change oils regularly. 8. Dispose of oils CORRECTLY. ‘SAFE OPERATION OF LATHE CHUCKS All workholding devices must be clearly marked indicating the maximum safe RPM. This must not be exceeded. It must be noted that the maximum RPM marking usually assumes ideal working conditions. Lower maximum speeds should be used typically for the following reasons. They apply only to chucks in sound condition, Ifa chuck has sustained damage, high speeds may be dangerous. This applies particularly to chucks with grey cast iron bodies wherein fractures may occur, The gripping power required for any given application is not known in advance. ‘The strength of the component being gripped, the area of the grip, the balance of the workpiece ete, will all have a major effect on the safe maximum RPM that can be usedOPERATING SAFETY ‘There is the possibllly of the workpiece becoming insecurely gripped due tothe Influence of e@ centtifugal force under certain conditions. The factors Involved Include:~ (a) Too high a speed for a particular application. i (b) Weight and type of gripping jaws if non-standard. | (0) Radius at which gripping jaws are operating. | . (4) Condition of chuck - Inadequate lubrication. | (©) State of balance. : | (f) The gripping force applied to the workpiece in the static condition. ; (a) Magnitude of the cutting forces involved, (h) Whether the woikplece le gripping externally of internally | Careful attention must be paid to these factors. As they vary with each particular application, a manufacturer cannot provide specific figures for general use, the factors involved being ‘outside his control. viOPERATING SAFETY ON MACHINES WITH VARIABLE SPEED DRIVE. NOTE THAT THESE MACHINES ARE DESIGNED TO ALLOW FAST AND EASY CHANGE OF THE SPINDLE SPEED. TAKE CARE TO ENSURE THAT THE WORK PIECE IS SECURE AND THE MAXIMUM SAFE SPEED FOR ANY OPERATION IS NOT EXCEEDED. : ALL MACHINES BECAUSE OF THE POSSIBILITY OF BODILY CONTACT AND WHIPPING, ESPECIALLY. WHEN.. SMALL.DIAMETERS OF "MATERIAL ARE USED, BAR STOCK MUST ‘NOT, UNDER ANY CIRCUMSTANCES, BE ALLOWED TO EXTEND BEYOND THE END OF THE HEADSTOCK SPINDLE WITHOUT THE USE OF SPECIAL GUARDING AND ADEQUATE SUPPORT.OPERATING SAFETY OPERATING SAFETY PRECAUTIONS 4. Keep the machine and work aroa neat, clean and orderly. 2. Keep all guards and cover plates in place and all machine cabinet doors closed. 3. Never lay anything on the working surfaces of the machine, where it may foul with I rotating or moving parts. 4, + Do not touch or reach over moving or rotating machine parts. 5, _ ENSURE YOU KNOW HOW TO STOP THE MACHINE BEFORE STARTING:IT. | 6. _Donot operate the machine in excess of Its rated capacity. | 7. Donot wear rings; watches, tles or loose sleeved clothing. 8. STOP MACHINE IMMEDIATELY ANYTHING UNEXPECTED HAPPENS. I 9, DO NOT interchange chucks or other spindle mounting Items without checking for i correct locking. | 10. Do not use other workholding devices without checking for compatability with @ 600 Lathes Ltd, and workholding mariufacturer, : 11. Check toad capacity of revolving centres for current application. 12, Isolate machine when leaving it unattended.OPERATING SAFETY GENERAL PRINCIPLES CONCERNING OPERATOR SAFETY FOR ALL TURNING MACHINES (1) Bo not grip a component with grease or oil on it Grip all components firmly. Do not attempt to hold components that are too awkward or too dificult to hold. Do not hold components that are too heavy for the machine. Know how to hold components properly when iting, (2) Be sufe to clean oil or grease from hand tools, levers and handles. Bo sure there is enough texture onthe surface of the hand toc! or ever handle for proper safe hand contact, (8) Grip hand tools and lever handles firmly. Always choose the proper hand tool and appropriate grip position on the lever handle, Do not use hand tools or lever handles in an awkward position. Do not apply excessive force. (4) Always use the recommended gripping position to grasp hand tools and lover handles. (8) Do not allow tuming or hand tools to be caught in the chuck or other holding device. (6) Do not use broken, chipped or defective tools. (7) Be sure work piece cannot move In chuck or other holding device, (8) Beware of irregular shaped work pieces. (8) Beware of large burrs on work pieces. (10) Always select the correct too! for the job, (11) Do not run the machine unattended, (12) Do not use tools without handles. (13) Always support the work piece as necessary using chucks, steadies and centres, (14) Correctly locate tool in socket heads and screw siots, (15), Beware of obstructions that prevent complete tightening of sorews - ensure sorew is tight. (16) Do not rush work, viiOPERATING SAFETY (47) Never substitute the wrong size tools if the correct sized tool is not available or cannot be located in the shop, (18) Do not move guards while lathe is under power, (19) Do not place hand or body in path of moving objects. Beware of moving lathe parts that can fall, Bo ae of where you are moving your hand or body in relationship to the lathe. Beware of holding a tool or other parts inserted in or attached to the chuck or work piece. Be aware of hands or other parts of the body that.may in-position to be hit by a chuck or work piece. . (20) Beware of accidentally moving levers, clutches (where applicable) or turning the power on, (21) Know the function of each and every control. (22) Never place hand,on chuck or work piece to stop rotation of the spindle. (23) On machines with clutch drive make sure clutch Is completely disengaged on stopping, and kept properly adjusted. (24) Make sure power has been turned off when lathe is unused for sometime. (25) Allow chuck to stop before opérating It. (26) Always check chuck area for chuck keys and loose jitems. (27) Never start spindle with chuck key in the chuck, ‘ (28) Do not allow distractions to interfere with lathe operations. Do not operate lathe whilst talking. (29) Beware of lathe dangers when attending to other aspects of lathe operation, eg. whilst operating tailstock, (80) Beware of loose clothing near the rotating parts of the lathe. (81) Boware of loose hair near the rotating parts of the lathe. (82) Boware of performing another operation while in close proximity to rotating parts on the lathe, viiiOPERATING SAFETY (83) Always attend to filing and deburring operations, ‘Always pay attention to file or deburring tools close to the chuck. Files and deburring tools may catch on chuck. (84) Beware of clutch (where applicable) position when jogging the spindle to different, positions for gauging. (38) Beware of hands resting on clutch levers. (86) Be sure lathe is in neutral position when placing gauges on components gripped in the chiuok, (87) .Be sure motor (on machines with clutches) Is not running when using gauges on the machine. (38) Always wear protection before operating the lathe, Always wear the correct protection before operating the lathe. Never remove protection for even a short time when operating the lathe, Wear protective devices correctly, Know the correct way to wear protective devices. (39) Beware of material flying from the lathes. (40) Keep protective guards at the point of operation. Know how to set or attach protective guards properly. Never use the wrong protective guard. Know how to select the proper guards, (41) a) When the chuck and workpiece are in motion never reach over, under or around a work piece to make an adjustment. b) Never reach over, under or around a work piece to retrieve anything, ©) Beware of where you leave your tools during set up. d) Never reach over, under or around work plece to move hand tool/lathe to another position. €) “Never reach over, under or around the work piece to tighten a lathe part. f) Never reach over, under or around work piece to remove swarf,OPERATING SAFETY (42) Know the proper procedure for applying loads. Never apply force from an awkward position. (43) Never mount a work piece too large for the lathe, (44) Never mount a workpiece too large for the operator to handle, (48) Use the equipment necessary for handling workpieces. (46) Never apply undue force on the accessory or control lever. (47) Socure aill work pleces. (48) Secure all jaws, nuts, bolts and locks. (49) Always use the correct equipment. (60) Never take cuts beyond machine's capabillty, (61) Never use excessive force in polishing, filing and deburring. (62) Always use the proper hand tool to remove swart. Never hurry to'remove swart, Beware of swarf wrapped around the chuck or workpiece. (63) Never change gears by moving them with your hands. (64) Beware of toolsilathe parts falling on controls,OPERATING SAFETY CHUCK GUARDS The lathe is supplied with a fully interlocked chuck guard which is suitable only for uso with the standard chucks normally supplied with the machine. This chuck guard must be In the fully closed position before the spindle is permitted to run. -a) b) In the event of larger chucks being fitted to the machine an alternative chuck guard must be used which is appropriate to the chuck diameter, Note: * Its not recofmmended that chuck jaws extend beyond the outside diameter of the chuck and.inthese cases interference with chuck guards may oocur, For safe operating practices always ensure that chuck jaws do not extend beyond the outside diameter of the chuck, In the event of a faceplate being used on the machine the normal chuck quard must be removed from it's mounting and if deemed necessary by the user alternative safe guarding facilities provided which are appropriate to the particular situation. This can only be determined on a case by case basis when using faceplates and is therefore the responsiblity of the user. xiOPERATING SAFETY Accidents at Metalworking Lathes @ using Emery Cloth i Danger: Even with long strips of cloth there is a danger of trapping. Hazards ‘A high proportion of all accidents at (a) the finish being sought is only cosmetic. metalworking lathes involve the use of emery For such finishes the component may be | cloth and result In injuries such as broken held in one hand and polished by emery and, occasionally, amputated fingers. cloth held in the other. Altematively a Emery cloth is used to deburr, polish or size linishing belt or machine may be used; a wide range of oylindrical, tapered and threaded metal components while they are (b) a sizing operation can be successfully rotating in lathes. performed either by tuming or by further Most accidents happen when each end ofa. ~ operations..in a dedicated polishing, strip of emery cloth is held in separate hands linishing or grinding machine, and passed around the back of the component being 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 rotating in a lathe, Such operations may not be necessary Emery cloth should never be held loose in the hand. xiiIf the required tolerance is only achiev- able by the use of emery cloth against rotating components, then the emery cloth should be applied using either: (a) abacking board of goodquality woods or (b) atoolpost ontowhich theemerycloth may, be placod; or (©) a ‘nutcracker’ consisting of two backing boards which are lined with emery cloth and joined at end and: - shaped so that they rey encom pass the surface to be linished; or (d) hand-held, abrasive-impregnated wire brushes. Where none of the above methods is reasonably practicable and itis necessary touse emery loth forpolishing the outside diameters of components, the emery cloth should be usedin long stripswith one end passed beneath the component, Force should be applied by pulling both ‘ends of the cloth upwards, never allowing the cloth to go slack or to wrap around either the operator's finger or the compo- nents, Forpolishingthe ends of components, only. very short lengths or pads of cloth should be used which are incapable of causing entanglements. Gloves should neverbe worn when polish- ing is being carried out, OPERATING SAFETY a (a) Sticks used in this way must be strong and of good material. (b) The use of a toolpost completely removes all risk of injury to the hands, (0) Using the ‘nutcracker’ method - a much better way of polishing. Fron the United Kingdom, health & safety executive Engineering Information Sheet No, 2INSTALLATION The approximate weight of the machine is - 1250mm- 50" between centres 1500Kg - 3300 Ib Always ensure capacity of equipment is adequate before attempting lift. Preparation and Safety Checks REN oe Remove all items of loose equipment. “Clamp tailstock securely at the tailend of the bed. Clamp saddle to bed. Ensure eyebolts, shackle pins and securing screws of liting equipment are correctly tightened. : Only use the correct equipment. DO NOT SLING AROUND BED. if Leadscrewscrew and splineshaft may-be bent.or. damaged:«...... LIFTING 1 Position sling complete with protective sleeve into cutaway at the bottom of thofirst angled web nearest to the headstock. (Fig. 1A) Protective Sleeve hot shown To ensure better balance the sling should be away from the front of the Pour machine. me Carefully lift the lathe clear of ground and if necessary reposition the saddle to achieve better balance before lifting further.INSTALLATION TEN RULES FOR SAFE LIFTING 4. Never overload the equipment. 2, Never use damaged slings. 3. Position the sling correctly. The sling must not be placed round sharp edges, do not let it slide over comers or along edges. 4; Do not drag goods in the sling. 5. Position sling correctly to ensure easy removal alter use. Use smooth-rounded hooks having ai inside radius of not less than 60mm. Avoid placing more than one sling on the same hook. 8. Keep away from alkalis and acids, @. When lifting heavy loads with more than one sling,remember that the total weight may not be evenly distributed. 40. Remember that vibration during transport can cause friction between sling and machine - use protective sleeves, Sling are made from 100% polyester. Each sling is clearly labelled with the safe working load and the safety factor is 6:1. All slings are colour coded for increased safety. For lifting rough or sharp edged loads we recommend the use of protective sleeves. SAFETY REQUIRES PERMANENT SUPERVISION We recommens the following procedure ‘1. All equipment should be examined by one person only. 2. Lay sling on a flat surface in a well lit area, 3, Examine both sides of the sling. 4, Slings must be examined over the whole length and In the eyes. | @ 1INSTALLATION INSTALLING Locate the machine on a flat, level solid foundation, allowing sufficient area for easy working and maintenance. The lathe may be used when free standing but for maximum performance it should be bolted to the foundation. FOUNDATION PLATES 7 Whether the machine is to be a free standing or fixed installation the eight jacking bolts MUST BE POSITIONED on eight stoo| plates. The dimensions of the plates should be 1mm (6/8") depth and of approximately 50mm (2") diameter. FREE STANDING Position the lathe on the foundation and adjust each of the eight jacking bolts in the plinths to take an equal-share of the load. Then level the machine using a precision level. FIXED INSTALLATION Position the lathe over eight bolts (5/8” or 16mm dia) set into the foundation corresponding to the dimensions in the plinths as shown on the foundation plan Fig.5. Adjust each of the jacking bolts to take an equal share of the load, level the machine then tighten ‘onto the holding down bolts. Re-check the bed level. LUBRICATION CHECKS Ensure that both the headstock lubrication system and gearbox are filled with Shell T37 (ISO VG 87) oll, to correct level and that the apron reservoir is filled to the level of the sight window with Shell Tonna TX 68 (ISO VGT 68) oil. Cll compound slide and tailstock through oilers fumished. Before each working shift, operate the manual lubrication pump to ensure adequate lubrication of carriage slideways. Refer to Lubrication Chart in Service and Maintenance Section for further information. HEADSTOCK SPINDLE BEARINGS All headstock spindles have been submitted to a running in procedure during assembly. Itis however recommended that further running in is performed of the headstock bearings before any prolonged high speed rotation is undertaken. Recommended speeds and duration: 15% of Maximum Speed for 1 hour. 50% of Maximum Speed for 80 Minutes, 80% of Maximum Speed for 30 Minutes.INSTALLATION CLEANING Before operating the machine remove the anti - corrosion coating, from ail slideways, the leadsorew feed shafts and the end train geer, (see Fig, 2) using only white spitit or parafin. Do NOT use-non-approved solvents i.e. Cellulose solvent’ or petrol; as they are hazardous and -will damage the paint finish. iil all bright, machined surfaces immediately after cleaning; use‘ heavy oll or grease on the end-train gears. Operate the slideways lubrication pump, mounted on the front of the apron several times to ensure that the last traces of anti-corrosion coating are removed from under the bedway wipers and slide edges. LEVELLING Using an engineers precision level (typical sensitivity 0.05mm/m ) mounted on the cross-slide (Fig. 3) level the machine end-to-end and front-to-back by adjusting the relevant jacking bolts. Align transversly as shown in Test No. G1 in the accuracy chart in order to eliminate “wist”.INSTALLATION ELECTRIC SUPPLY CONNECTIONS INPUT VOLTAGES ‘Three phase 220/440vAC #10% and 380/415vAC#10%, 50/60 Hz, Recommended Fuses:- 220 volts supply -35 amps '380/415/460 volts supply ~20 amps Fig Power should be supplied from a separate external fused isolator, the line entering the electrical cabinet at the base of the cabinet and connected to the terminals of the machine isolator. An earth lead must be used. (Fig.4) Main motor rotation must be counterclockwise, viewed from the motor. pulley end. The correct direction of spindle rotation may also be confirmed by engaging the forward clutch, With the clutch lever up the spindle should turn in the conventional forwards direction should the motor be running in the wrong direction switch off mains at the external fused isolator and interchange any two of the three phase-tines into the machine isolator. A wiring diagram Is Included in the servicing and maintenance section. The coolant motor is left electrically disconnected for transportation. This must be re-connected into the terminals marked U3, V3 and W3 in the electrical cabinet.‘A @ FIXING HOLES #16 B-} unckNG PosTONS Wis INSTALLATION FOUNDATION PLAN © 825 FOR COOLANT TANK WATHORAWL FOR SWARF_TRAY WITHDRAWL 1092 7s FOR TALSTOCK REMO\ 1250 LENGTH MACHINE” ‘2aGe OVER PLNTHS (1250 LENGTH WAGHNE)INSTALLATION CHUCKS AND CHUCK MOUNTING When fitting chucks or faceplates, first ensuré that the spindle nose and chuck tapers are clean; mount the chuck and ascertain that the cams lock in the correct position. When mounting anew chuckitmay be necessary to reset the camlock studs (A). To do this remove the caphead locking ‘screws (B) and set each stud so that the scribed ring (C) is flush with the rear face of the chuck and with the circular scallop in line with the locking screw hole (see inset). Now remount the chuck or faceplate on the spindle nose and tighten the six cams in turn.When correctly tightened the camlock line on each cam should be between the two “V" marks on the spindle nose. any of the cams do not tighteri fully within these marks, remove the chuok or faceplate and ro~ adjust the stud as indicated in the diagram. ‘Once a chuck has been correctly fitted it may be stamped toalign with the spindle reference mark for subsequent re-mounting in the same position. WARNING Only high speed chucks to be used with this machina, Take careful note of speed limitations when using face-plates. The 534mm (21") diameter face plate for gap bed use should notbe run at more than 470 rev/min. and the 356mm (14") diameter faceplate should not be run at more than 670 rev/min. [REFERENCE MARK ON SPINDLE NOSE connecr CANLOCK Une BETWEEN ARFOWS fe] os e) C wrowa waona ‘TUN STUD TuANsruD— | INONE TURN OUT ONE TURNOPERATING : | 7 | LATHE SAFETY @ BEFORE ATTEMPTING TO START THE MACHINE READ CAREFULLY THE i LATHE OPERATING INSTRUCTIONS ON PAGES 10 TO 17 OF THIS MANUAL. . IN THE INTERESTS OF SAFETY PLEASE READ THE OPERATOR HEALTH AND SAFETY GUIDANCE | NOTES ATTHE BEGINNING OF THIS MANUAL. Some of the key points aro: ft | 4. Ensure you know how to stop the machine before starting It. | 2. Stop machine immediately anything unexpected happens. 3. Ensure speeds, feeds and depths of cut are compatible with the component and the holding devices. | 4, Do not touch tooling, chuck or workpiece when spindle is revolving. 5. Wear and utilise suitable protective clothing and equipment. —w—OPERATING CONTROL LAYOUT 1. Emergency Stop Buttori 15. 2. Spindle Speed Selectors 16. 3, Main Motor Push Button 17. 4, Threading Data Plate 48, 5. Brake Release Push Button * 19. 6. Coolant Pump ON/OFF Switch 20. 7 Main isolator (at rear of machine). at. 8. Feed Data Plate 22, 9. Feed Selector Dial 23. 10, Feed Selector Levers 24. 11, Leadscrew/Feedshatt Reversing Lever 25. 12, Top -Slide Locking Screw’ 26. 18. Cross-Slide Locking Screw 27, 44, Carriage Locking Bott Tallstock Locking Handle Tailstock Barrel Locking Handle Tailstock Handwheel Tailstock Clamp Bolt Tailstock Set Over Screws Thread Dial Indicator Saddle Traverse Handwhes! Feed Direction (Axis) Selector Feed Engagement Lever Leadsorew Engagement Lever Spindle Control Lever Manual Centrallsed Lubrication System Interlocked Chuck Guard eeOPERATING ELECTRICAL CONTROLS (Fig. 6) Apart from the main isolator all electrical controls are fitted to the front face of the headstock. To start the main motor, switch on the main isolator, reset the emergency stop (A) then ensuring that the clutch lever is in neutral, press the main motor button (B). The motor will =, start running and the indicator lamp will light. J The spindle brake may be released by pressing the brake release button (C) continuously. The coolant pump may be switched on by» turning switch (D). “To stop the main motor, the emergency stop button is pushed in, Reset to allow starting by normal sequence. Fig. © © © ® SPINDLE ROTATION (Fig. 7) Selected by means of the apron mounted clutch engagement lever is moved to the right and up for forward rotation. Retuming to the neutral (central) position operates the spindle brake, Reverse spindle rotation is obtained by moving the lever downwards. “SPINDLE BRAKE A fail safe electromagnetic brake is provided and braking is automatically provided when the clutch lever is retumed to the neutral position or power is lost to the machine. "SPINDLE SPEEDS (Fig. 8) Spindle speeds are selected by means of the lever and knob Assembly mounted on the headstock, the 16 available speeds are shown directly on the dial face (A). CAUTION: DO NOT MOVE SPEED SELECTOR CONTROLS WHILST THE SPINDLE IS MOVING. — : 'OPERATING THREAD AND FEED SELECTION All threads and feeds directly available from the gearbox are shown on the data plates fitted to the headstock and change gear cover (Fig. 9) together with the relevant end gear train combinations and lever settings. a a Fig. 9 CAUTION : The coarse thread ranges of G and H should notbe selected when using the high spindle speod * range. The end gear trains should be arranged as in the diagrams shown on the data plate, For-any other threads or pitches not shown on.the data. plate. our Technical Department is available to specify the most convenient change gearing required. LEADSCREW REVERSING Using lever (A) on the headstock (Fig. 8) the direction of rotation of both leadscrew and feedshaft may be reversed. This allows the leadscrew nut to be permanently engaged during screw cutting and the direction’ of both feed and threads to be reversed whilst the spindle is running, _ CAUTION: When using the reversing lever the spindle speed should not exceed 175 R.P.M. aeOPERATING METRIC THREAD DIAL INDICATOR (Fig. 10) Thisis supplied when the machines fitted with a metric leadscrew and allows the majority of metric pitches shown on the data plate tobe cut by engaging and disengaging the leadscrew nut for each pass, ‘The correct pinion must be’ meshed with the leadscrew and tengagementofthe leadscrewis made atthe dialnumbertosultthe pitch of thread to be cut. Matric pitches not divisible Into the pinions supplied, D.P., module and inch threads must be cut with the leadscrew Ieft’ permanently engaged and changing direction by reversing the main spindle, ‘The information plate on the dial indicator shows:- ~ 1, Pitch to be cut in mm. Fig. 10 2. The number of teeth on the pinion gear which engages with the leadsorew. 3. The dial lines at which the leadscrew may be engaged, INCH THREAD DIAL INDICATOR (Fig. 11) This is supplied when the machine is fitted with an imperial leadscrew. The plate (Fig. 11) shows the T.P.I, to be cut and the dial ines at, which the leadscrew may be engaged. For metric threads, D.P., module and certain fractional inch threads the dial cannot be used, ‘These threads must be cut with the leadscrew left permanently engaged and reversing direction by reversing the main spindle See previous section, MULTI-START THREADS A multistart thread can be cut on a lathe in three basic ways. Fig. 11 1. By repositioning the compound (top) slide one pitch forward for each start. Note the slide is normally set at 90 degrees to the axis of the cross-slide. The accuracy of this, method depends on the skill of the operator by indexing the chuck on the camlock studs. of the thread to be cut, By using an accurately divided driver plate and tuming the workpiece one division for each start. With camlock mounted chucks two three and six start threads may be cut By advancing the driver geara calculated amount to advance the spindle by one pitch eatOPERATING APRON AND SLIDE CONTROLS Apron and slide controls (Fig. 12). In addition to the manual operation of the saddle by rotating apron handwheol (A), the cross-slide handwheel (B) and the topslide by handwheel (C), powar feed |s available to the saddle and cross-slide, by engaging lever (E). 1, Push pull knob (0) selects surfacing or sliding feeds. Push in for surfacing and pull out for sliding feeds, 2. Feed engage lever (E) is raised to engage whichever direction of feed is selected. 3, Lever (F) is used to engage the leadsorew nut for screw cutting, 4. _ For reversal of feed and thread directions there is a lever mounted on the headstock, FEED TRIP ADJUSTMENT - A trip mechanism is incorporated in the apron enabling the saddle to power feed up to fixed stops. The loading at which the apron trips out has been pre-set during construction arid should not be altered. The apron handwheel (A) can be disengaged from its gearing during power operation or when screweutting by pulling the handwheel out, It is recommended that the automatic feed trip mechanism Is NOT used below spindle speeds of 500RPM. SADDLE LUBRICATION - Knob (G) operates the apron and slideways lubrication pump, which ensures that the bedways, cross-slide ways and nut are adequately lubricated, To ensure that the system Is primed operate the pump until oll can be seen on the bedways and small tell-tale hole ‘on the saddle, Under normal use the pump should be operated twice before commencing work. CROSS-SLIDE AND TOPSLIDE - The handwheals carry dials graduated in either inch ormetric dimensions. The cross-slide dial is graduated to indicate changes in workpiece diameter and topsiide is graduated to indicate actual movement. SADDLE LOCK SCREW - This enables the saddle to be locked to the bed for facing or parting off operations. : ‘CROSS-SLIDE LOCK SCREW - This enables the cross-slide to be locked in a fixed position. “SLIDE LOCK SCREW - This enables the top-slide to be locked in position. poreOPERATING ! TAILSTOCK (Fig. 13) @ The tailstock may be clamped to the bed-by means of clamp lever (A) additional clamping may be obtained by tightening nut (B) located in the tailstock casting. This clamping nut should be; released before attempting to move the tallstook and after the need for additional clamping. The tailstock barrel is locked by means of lever (C). | Fig.13 Fig.14 The tallstock can be set over for the production of shallow tapers or for re-alignment, i Set over adjustments achieved by tinclampingtallstock lever (A) and nut. Slacken rearlocation screw (E) one turn (Fig. 14). Adjust screws (D) at each side of base by slackening one and ightening the other to laterally move tailstock across the base. Re-tighten the rear location screw. The barrel is graduated in inch and metric dimensions. : ‘The dial on the tailstock handwheel is graduated In elther Inch or metric dimensions. : COOLANT The coolant pump Is operated by an ON: and OFF switch located on the headstock. The flow of coolant is controlled by means of the tap fitted to the standpipe. ‘The coolant tank is located atthe back of the machine and has a capacity of $2 litres (8.5 US gallons). Any commercially available coolant may be used - suitable for the tooling and type of material being cut. —6—OPERATING GAP PIECE REMOVAL (Fig. 15) Fig. 15 REMOVAL PROCEDURE 4) Clean area around gap. 2) Remove chuck or any work holding device. 3) Release alignment bolt locknuts (A). 4) Fully retract alignment bolts (8). 5) Release holding down bolts (C). 6) Protect leadscrew 7) Carefully remove the gap piece avoiding damaging the leadscrew and gap piece mating surfaces. NOTE: eed > 1 t ' REFITTING PROCEDURE 1) Clean area around gap. 2) Ensure machine is level. 8) Ensure all mating surfaces are clean. 4) Carefully slide gap piece back into position. 5) Lightly bottinto position, aligning the ways by hand and lightly tapping the gap with a hide hammer, 6) Finally position the gap by means of the alignment bolts (B), being careful not to overtighten (maximum torque ft-pounds or 7 NM). 7) Tighten holding down bolts (C). ‘The two soft taper dowels included in the gap piece are provided to give an initial location ‘only when refitting the gap piece. They should be only ‘lightly fitted into their holes when the refitng procedure is undertaken, as detailed above. Only after re-machining of the holes using a taper reamor should the pins be tapped home firmly into postion. (This is an optional process when refitting the gap piece and under normat circumstances it is not necessary). ogoLATHE ALIGNMENT : With the lathe installed and in running conditionwe recommendacheckonmachine alignments before commencing work. Check alignment and levelling at regular periods to assure continued accuracy, HEADSTOCK CHECK (Fig. 16) (Onlytobecarriedoutaftercheckingmachino level), Take a light cut over a 150mm (6") length of 5mm (2") diameter stool bar held in a chuck (but not supported at the free end). Micrometer readings at each end of the tumed bar A and B should be within 0.01 mm,(0,0004").. LL an — f- a ‘comm LP |_am 160mm, Fig. 16 To correct a greater difference in readings loosen the fourheadstock screws (A) shown in Fig. 17 then adjust the set over pad C to. pivot the headstock about the dowel B. Tighten all securing screws after each adjustment. Repeat the test cut and alignment check ‘until the micrometer readings are within tolerancel, SERVICING AND MAINTENANCE It may be necessary to release the swing - frame clamp nut D TAILSTOCK CHECK (Fig.18) Using a 300mm (12") long ground steel bar mounted between centres, check the tallstock alignment by traversing a dial test indicator along the centre line of the bar. To correct any error use the set over adjustment procedure as shown in Figs. 18 and 14 on page 15 of this manual :SERVICING AND MAINTENANCE @ END GEAR TRAIN (Fig. 19) Drive from the Headstock to the Gearbox Is transmitted through a Gear train enclosed by the Headstock End Guard. Intermediate Gearsare carried on the adjustable Swing Frame (A). Gears must be thoroughly oleaned before fitting and backlash should be maintalned at 0.127mm (0.005 in) for correct mesh. Lubiicate Gears regulatly with thick Machine Oiland apply Oil Can tothe intermediate Gear Spindle, Fig. 20 (witboutieedserew cova) e Fig. 19 DRIVING BELT The Vee Belt tension may be assossed by applying finger pressure to each belt in tum at point T midway between the two pulleys (Fig.18). For correct tension a deflection of about 10mm should be possible in each Belt. To adjust the Veo Balt tension - release the Lock Nuts on the Motor Platform Adjusting Screws and alternatively slacken one Screw and tighten the other against the Motor Platform until the correct tension is obtained then re-tighten the two Lock Nuts. LEADSCREW TORQUE LIMITING DEVICE (Fig. 20) ‘The transmission is protected against severe overload by a torque limiting device fitted to the left hand end of the leadscrew. This is set to a pre-determined slipping torque before the machine leaves our works, In normal usage the useris advised not to alter this setting but to to consult our Service Department in case of a problem. Adjustment may be achieved by: 1, Loosening the two locking screws (A) on the O.D. of the device, 2. Tuming the inner adjusting ring (B) (by means of the two holes in the R.H.face of the unit) clockwise to Increase slipping torque. 3, Re-tightening the two locking screws. To "feel" the slipping torque hold the apron handwhee! to stop saddle movement whilst the leadscrew is engaged. CAUTION : Keep cutting tool well clear of workpiece and spindle at a low number of revimin, when making adjustments, qo eaeSERVICING AND MAINTENANCE DRIVE CLUTCHES @ Two multi-plate clutches on the headstock clutch shaft provide provide drive for forward an reverse spindle rotation, : When correctly set, clutches should accelerate the spindle from rest to 2000 revimin. within Sto | 4 seconds when fitted with the standard 250mm(10 in.) diameter 3-jaw chuck : Before adjusting clutches ensure that the main drive belts are correctly tensioned. ACCESS 1. Switch off power supply at Mains Isolator, Disengage Clutches with Spindle Forward/ReverseControl Lever in neutral position. | 2, Remove Headstock Cover as follows:- Remove Rubber Mat. : Remove Fixing Screws. | Fig. 21 ADJUSTMENT (Fig. 21 and 22) i 1. Select Clutch to be adjusted, i.e, RH, for forward L.H. for reverse. 2. Slide back Knurled Lock Ring (A) and rotate one notch at a time in direction of arrow to tighten. 3. Reset look ring. NOTE: OVER ADJUSTMENT MAY CAUSE SERIOUS DAMAGE TO CLUTCHES.SERVICING AND MAINTENANCE CALIPER BRAKE UNIT considerable life expectancy is assured from the fail to safaty caliper operated spindle brake, depending on the duty cycle imposed upon it, and the attention to prescribed maintenance. BRAKE MAINTENANCE The two most important features being the Air Gap Setting and the Free Floating condition of the brake on its two mounting pins (B), Fig, 28 Tho Air Gap is factory set at 0.25mm (0.010"). This gap should be checked at regular intervals, of approximately 3 months. As the brake pads wear this gap will gradually increase, when the gap has reached 0.75mm (0.030") the brake should be adjusted as follows:— ADJUSTING AIR GAP (Fig. 23) (a) Stop spindle and isolate machine. (b) Remove change wheel guard. (0) Check air gap If adjustment is required proceed as follows:— (¢)_ Fit two M6 x 45mm socket head transit screws (A) in position shown and tighten. {e) Before proceeding, take note of brake body float on mounting pins (B). This should be of an easy rattle fit. () Release by two tuins, each of the three brake body locking scréws (C). Next turn each of the hexagon spacers (D) ant-clockwise by equal amounts, ie. screw pitch = 1.75mm, 1/6 tur (one flat) = approx. 0.3mm. Retighten locking screws, slacken transit screws and check gap.-This should be between 0.2 and 0.3mm. If not repeat the process, Finally tighten all three locking screws (C) to 9NM. (9) Check that the brake is stil a free floating fit on its mounting pins (B) and has not been misaligned when retightening the three locking screws, Ii necessary release screws and re-align. This is IMPORTANT, check again for free play of brake on mounting pins. (h) Remove the transit screws (A). aeSERVICING AND MAINTENANCE CHANGE GEAR SHEAR PIN (Fig. 24) Additional protection is provided by means ofa shear Shear Pin’ pin fitted betwean the final driven changé gear and © the gearbox input shatt. To replace shear pin isolate electrical supply and open end guard. jae Remove driven gear A exposing bushes B and C. Withdraw pin head and push remainder of shear pin through bush D; Replace bush B, insert new pin and refit driven gear. LJ Fig. 24 CAUTION:- Use only replacement shear pins of 3.175mm(1/8") dia. mild steel, 45kg/ ¢mm. (30 tons /? in.) tensile strength, SLIDEWAYS ( Fig.25) Tapered gib strips are fitted to the slideways of the cross and compound§slidesto eliminate the effects of wear, Toadjust the cross-slide, slackeritherearsorew and then tighten the front screw A, making only slight alterations at a time, and constantly check for a smooth action. Finally re-tighten rear screw. ‘The topslide is adjusted by means of a single sorew B, Fig. 25 ‘Tapered gibs are fitted to each wing ofthe saddle and.are adjusted by means of the single screws front and back. Ensure that the slideways are cleaned and lubricated before making any adjustment, Tum screws clockwise to take up any play avoiding over adjustment, which will resultin stiffjerky action on the slide, CROSS-SLIDE NUT (Fig. 26) ‘The cross-siide nutis ofthe backlash eliminatortype. To remove undue slackness or backlash In the nut assembly first remove the socket head grubscrew G agjacentto the nut fixing screws on the top face ofthe slide. Insert a strong screwdriver through the grubscrew hole and carefully tum the nut adjusting worm In a clockwise direction until ight. Slacken back slightly, and operate the oross-slide repeatedly through full travel, making small adjustments until smooth action is obtained. Replace grubscrew into top of cross-slide to prevent Ingress of dirt and swarf,SERVICING AND MAINTENANCE LUBRICATION HEADSTOCK (Fig. 27) Spindle Bearings, Headstock Gearing and Shafis are lubricated continuously from a distributor Box located beneath the Headstock top Cover. This is supplied by a Pump driven by the main Motor andisnot related to spindle speed, Evidence of supply is shown in an Oil Sight Glass located on the Headstock front face. N.B. The Lathe should not be operated unless oil can be seen to be flowing. ‘A Pipe retums oil from the Bottom of the Headstock to the oil Pump. Ensure that the oil level in the systemis kept topped up, through the filer (A) in the Oil Tank, Do not fill through Headstock Cover, Check oil jevel weekly and change the oi every year using Shell Tellus oll 37 (ISO VG 37). The headstock may be drained via the drain plug on the headstock face just below the return pipe (B) Fig. 27. System capacity is approximately 16 litres (28 pints). Fig, 27 Fig. 28 GEARBOX (Fig. 28) All gears are splash lubricated from an integral oil bath, An oil sight window is situated on the right hand end face of the gearbox. Top up or refill gearbox with Shell Tellus T37 (ISO VG 37) through filler elbow on LH. side of gearbox casting, To drain the gearbox unscrew drain plug C in the gearbox casting. The capacity of the gear box.Is approximately 2.6 litres (4.6 pints). APRON (Fig. 29) ‘The apron gears are splash lubricated from an integral oll bath. The apron also acts as a reservoir for the oil for the manually operated pump, which lubricates the bedways, cross slide ways and nut, When the oil level falls below the mark on the oil sight glass the system should be topped up through the filler plug in the saddle with Shell Tonna TX68 (180 VGT 68), The capacity is approximately 1,2 litres (2.8 pints). A drain plug is provided underneath the apron casting. Fig, 29 —23—SERVICING AND MAINTENANCE LUBRICATION CHART @ ! Grease Each Week- lack and End Traln Gears (Change wheels). Shell Alvanla RA. = Chuck (manual). Molycote *O* ! ll Each Week - Tailstock, Leadscrew, Endgear Bushs and Topslide. Shall Tellus T32 (ISO HV 32) ' so cet) a ak tT TH 0 ee ye jeadstock. Check Level and top up Each Week - Shell Tellus T 32 (ISO HV $2), Total Capeclty 16 hires, Gearbox. Check Level and top up Each Weok - Shell Tellus T22 (ISO HV 32) Total Capacity 2.6 litres, REGULAR ATTENTION ~ DO NOT MIX LUBRICANTS.~ Fortrouble free operation keepthelatheclean —_ Whenalternativelubricantsaretobe used, the and regulary maintained. system or reservoir should be drained and Where Oil Nipples are provided lubrication _ flushed out before refilling with the equivaler should be carried out as indicated on the grade Lubrication Chart. 1 BeeCONTENTS: STANDARD EQUIPMENT HEADSTOCK ASSEMBLY MOTOR MOUNTING ASSEMBLY | CHANGEWHEEL ASSEMBLY GEARBOX ASSEMBLY ‘APRON'ASSEMBLY SADDLE / SLIDE ASSEMBLY TOPSLIDE ASSEMBLY TAILSTOCK ASSEMBLY THIRD ROD LINKAGE ASSEMBLY LEADSCREW COVER ASSEMBLY GAP BED, PLINTH AND RACK ASSEMBLY HEADEND GUARD ASSEMBLY INTERLOCKED CHUCK GUARD ASSEMBLY BELTS AND PULLEYS ASSEMBLY HEADSTOCK LUBRICATION ASSEMBLY. COOLANT ASSEMBLY NAMEPLATES ASSEMBLY TRIMMINGS ASSEMBLY SHEET METAL ASSEMBLY ACCESSORIES ELECTRICS SPARE PARTS INDEX PAGEHEADSTOCK ASSEMBLY (1)HEADSTOCK ASSEMBLY tiem | _ Part Number : Description aty 1 80605908 | 40T &21T GEAR 1 2 ‘A832.0060A | 80/34T GEAR 1 3 ‘A892-0060A | 26/38T GEAR 1 4 ‘A832-0061A |, 25/40T GEAR 1 5 ‘4879-0008A | RH BRAKET GEAR SHIFT i 6 --a879-0006A | LH GEAR SHIFT BRAKET 1 7 A879-0905A | RH GEAR SHIFT LEVER 1 8 ‘A879-0007A | LHLEVER GEAR SHIFT 1 9 ‘4879-00004 | RH ROD 1 10 ‘n879-00044 * | LH ROD 1 1 ‘8852-00054 | CLUTCH SHIFT LEVER 1 14 0129-0039 CLUTCH DRIVING DOG 15 344-1373 277 CLUTCH GEAR 18 10984-0053 HEADSTOCK CASTING 1 19 Dig2.0882 HEADSTOCK COVER 1 20 132-1100 FRONT BEARING COVER 1 at 132.0610 BACK BEARING COVER 1 22 132-0691 COVER INNER BACK BEARING 1 23 0297-0052 FRAME LEVERS: 1 24 10709-0088 HEADSTOCK SPINDLE 1 25 0570-0988 HEADSTOCK PULLEY 1 26 943-0218 GASKET 1 28 ‘8624-00434 | 26T PULLEV/@RAKE DISC 1 29 JB-0060, CALIPER BRAKE 1 80 344-0926 271 GEAR 1 31 344-1358 75T SPINDLE GEAR 1 82 344-1359 56T SPINDLE GEAR, i 34 344-0937 227 GEAR 1 35 344-0986 3ST GEAR 1 37 0344-0995 237 GEAR 1 38 0344-0722 277 GEAR 1 39 344-0831 19T GEAR 1 40 Das4-o724 SITGEAR 1 a Bagayoa0s — | _TUBE NUT ENOTS 04-0279-06 1 43 441-0089 12X BXBOKEY 1 44 562-0178 LUBE PIPE 1 45 562-0177 LUBE PIPE 1 48 0562-0176 OIL SIGHT FEED PIPE 1 a7 004.0083 ADAPTOR 4 49 10699-0855 2ND SHAFT 1 60 Des9-0854 38RD SHAFT 1 at 699-0853, ‘SHAFT 1 55 10690-0876 SHAFT IDLER 1 56 0931-0226 THRUST WASHER, 1 ASSEMBLY + A100-0515G = 1SSUE7_: 19/087: SERIALNO. 1-HHEADSTOCK ASSEMBLY (2) @ aii) (eA) (60) Go) (33) G57) (si) God (94) E5e) (20) (63) (si) (68)G09 (69) (42) (60) Go) (GINGA) (4d) G49 G1?) (8?) (99 ASGENGLY + A100-0515 ; ISSUE @ ; 08.1086 : SERIALNO. i 1+ iitHEADSTOCK ASSEMBLY tem [Part Number ; Description aty 60 129-0023 CLUTCH-MATRIX ZO25DDW/o4 1 6 9344-1966 26T GEAR IDLER 1 62 0344-1968 Si CLUTCH 1 63 0708-0543 PULLEY SPACER 1 6 0708-0150, SPACER 2X1-1/4" 2 65 = 0708-0151 SPACER 1-5/8X1-3/16" 1 86 708-0362 SPACER CLUTCH 1 7 5708-0544 SPACER 4 8 ‘D699:0877 SHAFT CLDRIVING 1 69 Dss6-0344 NUT BACK BEARING 1 70 Ce-0080 caM 6 7 FS-0254 3/6" UNC X 3/4" CAP SCREW (SPECIAL) 6 2 est-o362 WASHER RETAINING 2 8 231-0393, ‘THRUST WASHER 1 7 91-0282 WASHER 1-1/2X7/16" 1 76 Dsee-0212 PLUG 62MM DIA 2 78 566-0211 PLUG 62MM DIA. 1 8 0566-0167 PLU 1 87 132.0767 COVER-SMALL BEARING 2 88 388-0153, BEARING HOUSING 1 89 988-0182 BEARING HOUSING 1 20 182.0175 BEARING HOUSING COVER 1 3, 566-0186 PLUG 1 95 943.0114 GASKET FRONT BEARING COVER 1 86 343-0164 GASKET REAR BEARING COVER 1 97 343.0048, GASKET : 2 98 343-0049, GASKET : 1 403 123.0128 CCAM DRUM 1 4104 123-0122 RCAM FACE 1 105 452-0286 LEVER CLUTCH CENTRE 1 108 0565-1256 PIVOT PLATE - CLUTCH LEVER 1 107 0041-0254 BAR EXT.SPRING 1 108 049-0354 BUSH/CLUTCH LEVER 1 409 Do4s-0952 BUSH LEVER PIVOT Hl a 647-0029, ROLLER 1 112 Ds60-0392 HINGE PIN 1 115 0560-0936 PIN SPRING 1 116 0931-0368 WASHER 1 119 De98-0856 ‘SHAFT ORUM CAM 1 420 0699-0850 SHAFT FACE CAM 1 ‘ASSEMBLY ; A100-05166 ; ISSUE7 : 19/097 + SERIALNO, telHEADSTOCK ASSEMBLY (3) ASSEMBLY: A100-0515 + ISSUEZ + 08.10.96 + ‘SERIALNO. tevHEADSTOCK ASSEMBLY item | Part Number Description ary 122 0848-0050 ROD GUIDE 2 124 557-0158, CLUTCH SHIFT PAD 4 125 299-007 GEAR SHIFT FORK 2 128 0299-0078 FH GEAR SHIFT FORK 1 127 ag9-0079 LH GEAR SHIFT FORK 1 tat D183-0261 COLLAR GUIDE 2 182 0741-0200 STUD PIVOT 2 493 1D050.0601 BRACKET PLUNGER 1 134 5670062 PLUNGER CAMS. 2 135 704-0199 SLEEVE CLUTCH SHIFTER 1 136 19343-0056, GASKET 1 137 726-0043, ‘SPEED SELECTOR i 138 Dest-o194 WASHER 3 199 0047-0175 BLOCK REVERSE BOX 1 140 o47-0105 BLOCK REVERSE BOX 1 v1 10897-0360 ADJUSTING SCREW-REVERSE BOX 1 142 192.0176 COVER DIAL 1 143 Do47-0147 BLOCK-DISC BRAKE MOUNTING 1 148 860-0903, PIN- REVERSE BOX 1 447 1560-0304 PIN - REVERSE BOX 1 148 0282-0038 SPEED SELECT DIAL 1 149 0837-0582 NAMEPLATE INDICATOR 1 150 0537-0588, NAMEPLATE SPEED RANGE 1 151 537-0584 NAMEPLATE SPEED SELECTOR 1 162 004-0084 ‘ADAPTOR 1 183 0132-0701 ‘COVER CLUTCH ACCESS 1 184 343-0180, GASKET CLUTCH COVER 1 187 344-1257 GEAR REVERSE BOX “i ! 188 ‘AB06-0858A | ‘SPACER SUB ASSY REV BOX z 1 159 ‘4808-05608 | GEAR'SUB ASSY REVERSE BOX 1 160 386-0127 HOUSING INPUT SHAFT REVERSE 1 161 ‘4206-05590 | HOUSING ASSEMBLY REVERSE BOX 1 182 ‘AB24-0031A | 18T PULLEY SUB-ASSY REVERSE BOX 1 163 061-0008 CLUTCH BOBBIN REVERSE BOX ae 1 164 3880128 HOUSING OUTPUT SHAFT REVERSE BOX 1 185 599-0788 INPUT SHAFT 1 168 De99-0789 OUTPUT SHAFT 1 467 ‘8624-00204 | 26T PULLEY SUB-ASSY-REVERSE BOX” 1 168 10708-0459 SPACER SHAFT A REVERSE BOX ’ i 168 0299-0067 ‘SHIFTER PAD REVERSE BOX. | : 1 170 41-0280 SHIFTER BAR REVERSE BOX . > 1 "1 699-0773 SHIFTER PIVOT SHAFT | : 1 172 659-0781 SHIFTER REVERSELEVER 1 478 0283-0023, SHIFTER DISC REVERSE BOX 1 174 10560-0295 SHIFTER PIN REVERSE BOX 1 175 0708-0468 SPACER REVERSE BOX 1 176 De46.0067 COOLANT THROWER, 1 179 8163-1781 12X16 SOCKET SET SCREW DO a ASSEMBLY : AT00-0515@ ISSUE7 : 19/0/07 + aviHEADSTOCK ASSEMBLY (4) e@ ‘are Pate: So Ou © ae Eh © ‘ASSEMBLY; A100-0515 ; ISSUE : 08.10.90 : SERIALNO. i devil@ HEADSTOCK ASSEMBLY. tem [Part Number 5 Description aty 180 FS.0946 M6 X 8 FULL, DOG POINT SOG, SET SCREW 2 181 FS-0500 Me X 10 SOCKET CUP POINT SET SCREW 1 182 FS.0600 Mi2 X 25 HEXAGON HEAD SCREW 1 183, PB.O110 +2" BSPT SOCKET PLUG 1 184 F8.0162 MB X 20 SOCKET HEAD CAP SCREW 6 185 | - FS-0092 YA X 10 SOCKET HEAD CAP SCREW 2 187 Ka.o190 6 X 9X 22 WOODRUFF KEY 2 188 8343-5041 6X6X 10KEY 1 189 |, KA-0340 8X7X 40KEY 1 190 86.0275 6002 22 BALL BEARING 2 191 8343-5081 5X5 X 16KEY 1 193 RA.0160 CIRCLIP DIN1400-24 EXTERNAL : 2 194 RA-O170 CIRCLIP DIN1400-25 EXTERNAL 2 195 RA0190 CIRCLIP DIN1400-90 EXTERNAL 1 498 RA-0070 CIRCLIP DIN1400-8 EXTERNAL 3 197 RA-0140 CIRCLIP DIN1400-20 EXTERNAL 1 200 BF-0010 MB14 20 DU BEARING 2 201 8346-1338, TIMING BELT REF 2704100 1 202 8346-1397, TIMING BELT REF 150100 1 203 F8-0050 (M12 DETENT) BALL DETENT SCREW 1 e ax | soaes ~ | couztempancove na seanea 206 BG-0470 (6006-22 DEEP GROOVE BALL BEARING 1 208 ‘8369-0060 CIRCLIP DIN 400-60 EXTERNAL 1 208 FAo126 CIRCLIP DIN‘400-18 EXTERNAL 1 210 Ba6sv0447 | CIRCLIP 1800-47 INTERNAL 1 ait 369-0455 CIRCLIP 100-55 1 at RA.O110 CIRCLIP DIN1400-15 EXTERNAL 2 218 18936-1228 BEARING 191093N/191152XC GAMET 1 : 219 8336-1322 BEARING 193075/193130P X1162A GAMET 1 220 8318-0416 6006 BALL BEARING 3 224 8913-0418 6007 BALL BEARING 2 222 BG-0340 (6008 BALL. BEARING 1 223 84-0080, 6206 BALL BEARING 4 os 290 8337-2035 BEARING INA REF NK28/30 2 : 231 8337-2040 BEARING INA REF NK30/20 i ~| 232 18937-2022 BEARING INA REF NK22/20 2 233 B414-s224. -| OIL SEAL 1 205 B4129013 | ORING 2 237 412-0140 ORING 4 28 A015 ORING 2 239 ©A-0080 OnING t 2a Barzoz0 | ORING 2 242 04-0170 ORING 1 \SSEMBLY:AV00-0515G : ISSUE7 + ia/a/a7 : SERIALNO. 1-villHEADSTOCK ASSEMBLY (5) (si) (59) (48) (3) God (38) Ged) G29) G49) Gad Ge: Ce Pr bt ® 5 line O® ASSENBLY + Ai00-0815 + issue? = 08.1096 + SERIALNO. tix@ HEADSTOCK ASSEMBLY tem [Part Number : Description ay, 244 A010 GIRCLIP DIN1400-90 EXTERNAL 1 245 RA.0260 CIRCLIP 1400-35 EXTERNAL 2 246 18363-0038, CIRCLIP 1400-38, 4 247 RA-0120 CIRCLIP DIN1400-16 EXTERNAL. 1 248 8362-0024 CIRCLIP 15/16IN DIA EXTERNAL 1 249 8362-0028 CIRCLIP 1 1/@IN DIA EXTERNAL 1 250 8969-0042 CIRCLIP DIN 1400 4 251 18363-0085 CIRCLIP 1400-85 EXTERNAL 1 252 A-0085 CIRCLIP 1400-0100 EXTERNAL 4 25a |» RA-0090 CIRCLIP DIN1400-12 EXTERNAL 2 254 8961-5046 CIRCLIP INTERNAL 55MM BORE 4 285 361-5052 CIRCLIP INTERNAL 62MM BORE 4 258 8363-0070 CIRCLIP DIN 1400 i 261 8365-1171 ‘SPRING FLEXO 123204 2 262 FR-0300, 86300 CAM SPRING 6 264 Lp-0280 BLANKING PLUG. 1 268 KA.0012 5X5X 18 KEY 2 267 8349-0012 8/6" X 6" X 5/8" KEY 1 268 Ka-0170 3X8 X 18 WOODRUFF KEY 1 269 |. KA-0920 40X65 X 18 WOODRUFF KEY 2 270 KA-0180 5 X7.5 X 19 WOODRUFF KEY 2 on 8343-5130, sex 8X20 KEY 1 272 D981-0370, ‘TAB WASHER INPUT SHAFT 1 25 B11 1-5099 M25 X 10 SPIROL PIN 1 276 Biit-2468 8/6 X 8/4 SPIROL PIN 2 at Bit t-5062 M4X 85 SPIROL PIN 2 279 FT-0374 Me X 30 SPIROL PIN 2 280 BI11-2516 04" X 7/8" SPIROL PIN 1 282 FS-0008 M4 X 16 SOCKET HEAD CAP SCREW 4 283 8123-2267 M2 X 8 SELFTAP SCREW 10 284 FS-0502 M6 X 12 CUP POINT SOCKET SET SCREW 2 285 FS-0584 M10 X 20 HEXAGON HEAD SCREW 1 287 8.0873 Mi0X 12.D0G POINT SCREW 3 288 FS.0110 MS X 10 SOCKET HEAD CAP SCREW 1 289 Fs.0182 ‘Me X 12 SOCKET HEAD CAP SCREW 4 By 290 FS.0196 M6 X 20 SOCKET HEAD CAP SCREW 6 tel 201 FS.0138 Me X 25 SOCKET HEAD CAP SCREW 5 aes 293 Fs-0164 M8 X 25 SOCKET HEAD CAP SCREW 3 ct 295 Fs.0426 M4 X 10 SOCKET COUNTERSUNK HEAD SCREW 2 298 Fs.0442 M6 X 18 SOCKET SCREW COUNTERSUNK 1 297 163-1761 Mi0X10 HEXAGON SOCKET DOG POINT SCREW 2 298 F3.0342 MS X 6.1/2 DOG POINT SOCKET SCREW 2 289 F8.0378 —-|_ M12 12 DOG POINT SCREW 4 [ASSEMBLY =; Af00-0518G + ISSUE7 ? 19007 : SERIALNO. dexHEADSTOCK ASSEMBLY (6) @ ' ‘ASSEMBLY; ATOO-0515 ) ISSUE® ; 081008 : SERIALNO, 1-xi@ HEADSTOCK ASSEMBLY item | Part Number : Description iy 201 Fs.0098 Mi X 20 SOCKET HEAD CAP SCREW 1 ao2 | B163-1694 | MAX SOCKET SET SCREW CONE POINT 4 303 | FS.0140 M6 X 30 SOCKET HEAD CAP SCREW 6 aoa | FSO146 Mo X 45 SOCKET HEAD CAP SCREW 40 aos | FS0151 M6 X 70 SOCKET HEAD CAP SCREW 3 308 | F9-0294 Me xX 12 BUTTON HEAD CAP SCREW n so | FS.0496 Ms X 12 SOCKET SCREW COUNTERSUNK 2 310 |. Biestea2 | MSX@SET SCREW 3 siz |" FSo198 Me X 20 SOCKET HEAD CAP SCREW "1 aia | F134 M6 X 16 SOCKET HEAD CAP SCREW 5 314 | FR-0520 COMPRESSION SPRING 1 316 18965-4996 SPRING ' 1 317 | FS-1040 Mi LOCKNUT 1 aie | FS0973 M12 LOCKNUT 2 319 | Baza-0200 | V8 BSPT HEXAGON SOCKET PLUG 4 szo_ | FP.0090 Ms WASHER 2 at 493.0802 | 9/6" ENOTS NUT S4-0155-09 4 az2 | PA.o060 9/8" SEAL 94-0156-08, 4 323 || pasatoo1 | OILSIGHT 1 e@ ses | rezrai0s | NYLON TUBE ont ses | Rea7-aio7 | NYLONTUBE or azo | PB.o040 a4"BSPT MALE/FEMALE 00% ELBOW 1 3e0 | PB.0020 al" BSPT DRAIN PLUG 4 at 0040128 | ADAPTOR. 2 833 | poat-o4o4 |] WASHER THRUST (AS REQUIRED) 1 seq _| psat-o405 | WASHER THRUST (AS REQUIRED) 4 335 | D9at-o40s | WASHER THRUST (AS REQUIRED) 4 4o7 | pest-ogge | THRUSTWASHER 1 «| fos | peatoset | THRUSTWASHER 1 “os | 6963.0008 "| CIROLIP DIN 1400-28 1 410 | Doat-o00 | THRUSTWASHER CLUTCH SHAFT 1 an ar17001% | Me WASHER 1 a2 | FS-o272 M4 X@ BUTTON HEAD CAP SCREW 1 ASSEMBLY 7 Atoo-0si66 1 ISSUET 7 190067 1 GERIALNO. 4-xitHEADSTOCK ASSEMBLY (7) REAR VEW OF HEADSTOCK. ASSEMBLY 7 AVGO-OB1S 7 ISSUED + 08.1088 + SERIALNO. 1extiiHEADSTOCK ASSEMBLY tem | Part Number Description aty ‘ASSEMBLY: A100 -05156 1SSUET 19807 = ‘SERIALNO. 1exivMOTOR MOUNTING ASSEMBLY sora voor ae Ss (613) TR/GH 10/94 A175—05016A175 - 0501G MOTOR MOUNTING’ ASSEMBLY TAIGH 104 A175- 05016 " BRIGHT WASHER M10 FP 0165, 16 MOTOR MOUNTING BLOCK B04 7- 0109 7 MOTOR MOUNTING BLOCK 047-0110 18 ‘SWING BOLT D697 - 0961 19 ‘SUPPORT BAR x oat - 0238 20 ‘SUPPORT BAR, Dodi - 0239 21 PLATE'60 Hz i ‘D565 - 0979 22. ELECTRICAL PANEL BAR Dost - 0240 23, HEXAGON SOCKET CAP HEAD SCREW M10 X 45 FS-0192 24 HEXAGON SOCKET CUP POINT SCREW M6 X 10 FS - 0500 25 SET SCREW WIPOINT M10 x 25 Biss - 1588 26 HEXAGON SOCKET CAP HEAD SCREW M12 X 95 FS - 0604 a HEXAGON HEAD SET SCREW M10 X 40 FS - 0590 28 LOCK NUT M16 FS - 0978 20 SAFETY WASHER M10" FO -0010 80 SAFETY WASHER VS-12, FO - 0030 31 SAFETY SPRING WASHER M16 Bit6- 2316 82 NYLOGNUTMIO” FS- 1010 33 BRIGHT WASHER M12 FP - 0070. 34 BRIGHT WASHER Mi FP -0090 Page 21CHANGEWHEEL ASSEMBLY TR/GH 10/94A155-0504A, CHANGE anc ASSEMBLY Ea ae Ee Ease He 4 [SWING FRAME 0720-0025 it VASHER M12 [FP-0070 9 |HEXAGON HEADED SCREW M12x25 FS-0600 Ww IHEXAGON HEADED BOLT M12x40 |FS-0876 12 ICLAMP WASHER |D708H008. 1 13 [TEE NUT (REAR) ID408HO06.1 14 ISHAFT-SLEEVE \D699-0793 15 WASHER, |D408H010. 1. 46 — |NUT (0408H007.1) IFA-0010 17 [SPACER |D40BHO08: 1 18 SLEEVE [0704-0123 19 WASHER: |D931-0349 20 |SPRINGWELL OIL NIPPLE 6mm jOc-0010 22 28T 1.75 MOD. CHANGE WHEEL (METRIC SET) 10344-1287 23 I93T 1.75 MOD. CHANGE WHEEL (IMP SET) [0344-1284 24 IS6T 1.75 MOD. CHANGE WHEEL (IMP SET) |D344-1285 25 [44T 1.75 MOD, CHANGE WHEEL (METRIC SET) 0344-1286 27 \48T 1.75 MOD. CHANGE WHEEL (METRIC SET) 10344-1299 28 72T 1.75 MOD, CHANGE WHEEL (METRIC SET) 10344-1251 29 847 1.75 MOD. CHANGE WHEEL (METRIC/IMP SET) ]D344-1252 34 I95T 1.75 MOD. CHANGE WHEEL (IMP SET) 10344-1254 32 98T 1.75 MOD. CHANGE WHEEL (METRIC SET) (0344-1255 34 847 1.75 MOD. CHANGE WHEEL (IMP SET) [0344-1252 35 |72T 1.75 MOD. CHANGE WHEEL (METRIC SET) [0344-1335 37 99T 1.75 MOD. CHANGE WHEEL (IMP SET) (D344-1305, 44 WASHER LOCK |B116-2228 45 STUD [D048-0160 46 SWING FRAME SPACER 10708-0489 47 JO RING DOWTY 202-511 (RMO91-16) jOA-0020 48 [GLACIER BUSH MB 1820DU IBF-0120 Page 34 TRIGH 10/94 A155-0504AGEARBOX ASSEMBLY (1) coger ee ge 1S) (zi) Goi) (=) (68) Gel) Gai) G)) (A) 2) GE wy Ge) @C * (01) (oe) (08) al) (€8) (ie) Ge OO) '32) (88) (22) (82) (62) (2) (@ ‘s2)(sz)(2) (28) (ze) (2 TR/GH 10/94 A703 — 0001 Page 4~iA703 - 001A GEARBOX ASSEMBLY ‘TAIGH 10194 A703 - 001A 1 GEARBOX CASTING D70sH001.2 2 ‘(GEARBOX GASKET (0703H002.2) GA-0670 4 TOP SHAFT D70sHo17.1 8 BOT GEAR - TOP SHAFT D703H022.1 6 19T GEAR- TOP SHAFT D703H021.41 7 SPACER. TOP SHAFT D70gH023.1 a 161/23 GEAR - TOP SHAFT D703H020.4 9 ‘82T GEAR- TOP SHAFT D703H019.1 10 9T GEAR- TOP SHAFT ‘D703H018.1 "1 PLUG D703H047.1 2 LOCATING BUSH BEARING DaosHort.4 14 INPUT SHAFT D70sH048.1 16 HOUSING D7osH049.1 16 ‘SPACER - INPUT SHAFT D703H034.1 7 197/207 GEAR D703H035.1 19 MIDDLE SHAFT D703H003.1 20 32T GEAR - MID SHAFT D703+1006.1 at ‘997 GEAR- MID SHAFT D703H004.1 22 421 GEAR- MID SHAFT 1D 703H008.4 23 24T GEAR- MID SHAFT D703H007.4 24 277 GEAR- MID SHAFT D703H008.1 25 23T GEAR- MID SHAFT D703H009.1 28 2AT GEAR - MID SHAFT D703H010.1 27 20T GEAR- MID SHAFT D70aHot4.1 28 16T GEAR - MID SHAFT D703H012.1 29 227 GEAR- MID SHAFT 9 703H013.1 30 ‘SPACER - MID SHAFT D703H015.1 at BEARING HOUSING D703H014.1 82 ADJUSTING NUT D703H016.1 34 ‘OUTPUT SHAFT D703H036.1 35 21T GEAR - OUTPUT SHAFT D703H038.1 36 BEARING HOUSING D703H097.1 37 SPACER ‘DooTH2-081 39 HOUSING D40aH033.4 40 ADJUSTING NUT D40aH034.4 a FRICTION SLEEVE D403H035.1 42 INNER RING D403H036.1 “4 BOTTOM SHAFT D70sH024.1 45 22T GEAR - BOTTOM SHAFT D703H029.1 46 22T SLIDING GEAR - BOTTOM SHAFT. D703H027.4 47 837 SLIDING GEAR- BOTTOM SHAFT — D703H025.1 43 227/227 SLIDING GEAR - BOTTOM SHAFT ‘D703H028.1 49 397 SLIDING GEAR - BOTTOM SHAFT D703H026.1 50 36T GEAR - BOTTOM SHAFT D703H030.1 51 BEARING HOUSING D703H031.4 Page 4GEARBOX ASSEMBLY (2) en ((03)x4 (70)x4 (5)x+ (68)x4(35) (02) x3 Page 4~iii “TR/GH 10/94 A703~0001ATO3 - 0001A GEARBOX ASSEMBLY ‘TRIGH 10/06 A703 - 0001A 82 PLUG (D403H037.1) PB - 0080 4 SELECTOR LEVER 0703H042..4 85 SELECTOR LEVER D703H043.4 56 ‘SELECTOR LEVER, D7oaHo44.t 87 ‘SELECTOR SHAFT D70aHodt.1 5B ‘SELECTOR SHAFT D70sHo4s.1 oy CAM SHAFT D70sH039.1 e INNER RING D4osHoss.1 63 ‘SELECTOR DIAL ‘D702H090.1 64 WASHER DaogHI11.1 65 ‘SELECTOR CAM D40sHO5e.4 66 SELECTOR SHAFT 1D703HO40.1 or SELECTOR LEVER (CAM) (D403HO60.4 68 SELECTOR LEVER (CAM) DaoaHiost.1 69 GEAR SHIFTER (D4caHos2.1 70 ‘CAM SELECTOR PIN (D403H062..1) FT -0620 n HANDLE b3a2-0137 78 GLACIER BUSH MB-25-30-DU BF -0160 cc GLACIER BUSH MB-20-25-DU | BF -0140 7 GLACIER BUSH MB-12-16-DU BF -0070 78 GLACIER BUSH MB-10-15-DU BF -0060 73 GLACIER BUSH MB-22-25-DU BF-0145 8t MJ17(6303) BEARING 8G - 0020 82 1L20(6204) BEARING BG - 0060 83 ‘XXLJ25 (6008) BEARING BG - 0050 4 BALL BEARING INA 61905 BQ - 0260 85 DEEP GROOVE BEARING 6002 BG -0270 86 ‘THRUST NEEDLE BEARING AXK 2542 BC-0130 88 ‘THRUST WASHER INA AS2542 BC-0120 90 WOODRUFF KEY 6 x 9 x 22 KA-190 at WOODRUFF KEY 8x 5x 13 KA-170 93 'O' RING RM 0416-30 (OA- 0220 94 ‘O' RING RM 0111-16 OA- 0040 95 ‘0! RING RM 0131-18" ‘OA- 0060 97 EXTERNAL CIRCLIP 5103-100 RA-370 98 EXTERNAL CIRCLIP 1400-20 RA-0140 99 EXTERNAL CIRCLIP 1400-19 RA-0180 100 | EXTERNAL CIRCLIP 1400-15 RA-0110 101 EXTERNAL CIROLIP 1400-14 RA-0100 4102 EXTERNAL CIRCLIP 1400-16 RA- 0120 403 | EXTERNAL CIROLIP 1400-12 RA- 0090 104 INTEPINAL CIRCLIP INA BR 82 RA-0440 Pago 41vGEARBOX ASSEMBLY (3) TR/GH 10/94 A703-0001 Poge 4-vA703 - 0001A GEARBOX ASSEMBLY tos | OWSEAL v.25 08-0090 jos | sTEELBALL7.0 uB- 0007 110 | SCHNORA DISC SPRING E5582 FR-0170 412 | 1/2" BSPT DRAIN PLUG PB- 0010 113 | /2"BSP M&F 90° ELBOW PB- 0055 114 | 1/2" BSP SOCKET PLUG PB-0110 115 | OIL WINDOW Ic4st0 (DWa081A) WA- 0020 117 | SPIROL FIN 10x30 FT-0470 418 | SPIROLPINGx35 FT-0730 119 | SPIROL PINS x24 FT-0230 121 |” HEXAGON SOCKET CAP HEAD SCREW MS x 20 FS-o116 122 | HEXAGON SOCKET CAP HEAD SCREW Mé x 20 F8-0102 123 | HEXAGON SOCKET CAP HEAD SCREW MB x 40 F8-0170 124 | HEXAGON SOCKET C/SUNK SCREW MS x 12 FS-0496 125 | HEXAGON SOCKET GUP POINT SET SCREW M4x4 FS-0486 426 | HEXAGON SOCKET CUP POINT SET SCREW MS x20 FS 0536, 127 | HEXAGON SOCKET C/SUNK SCREW M6 x 16, FS 0442 129 | HEXAGON SOCKET DOG POINT SET SCREW M8 x8 FS-0362 yt | MSNUT FS-0918 493. | BALL DETENT soREW M12 (SP 990) FS -0050 394 | CHANGE WHEEL BUSH D703H000.1 495 | MILO STEEL SHEAR PIN sfe2" x9/8" LONG D860 - 0197 136 | SPACER D7osHiot0.4 137 | NUT (O40aH007.1) FA-0010 493 | EXTERNAL CIRCLIP 1400-18 RA 0126 +43 | PANHEAD SCREW Max 16 (O403H054.1) F8-o7t4 ‘TRIGH 10104 A703- 0001A Page 4viAPRON ASSEMBLY (1) OES. | | encusn (64 21) (108) (108) (23)(2#) (22) (12) (28) G2) Sr). were (56 132) ( 16) (101) (18) (102) (20) (107) (110) (26) (18) (13) (ur) (20) (28) (23) Page 5-1 TR/GH 10/94 A704 ~ 0001A704 - 00014, APRON ASSEMBLY | 1 APRON CASTING (RIGHT HAND) ‘D704H052.1 7 2 ‘APRON GASTING (LEFT HAND) D70sH051.1 : 3 COVER PLATE D704HO53.41 ; 4 WORM BOX CLIP 10704H003.1 | 5 SPACER ‘p704H009.1 + | 8 WORM BOX LEVER D704HO18.1 7 LEVER BEARING COVER D704HOE9.1 8 GLIP HINGE PILLAR D70sHO84.4 9 CLIP HINGE PILLAR 704H062.4 10 HINGE PIN CLIP ‘D704H063.1 1 SPACER D704H075.4 42 END CAP DootHt-010 18 PISTON DasoHt-015 4 PUMP BODY DaatH2-001 18 PIN ‘D404H039.1 16 HANDWHEEL DETENT SPACER, DaosH057.1 7 ‘APRON HANOWHEEL SPIGOT ‘ 40sH063.4 18 WASHER D4do7HOI2A1 19 HOUSING ‘D704H093.1 20 ‘APRON HANOWHEEL D704H043.2 2 HANDWHEEL PINION SHAFT D70sHO71.4 2 68T GEAR D704H025.2 | 23 BUSH D704H026.1 2 RAGK PINION D704HO72.1 5 SLIDING PINION SHAFT 7odHo26.1 26 16T/AST SLIDING GEAR D704H020.1 or PINION GEAR D704H056.4 28 WORM GEAR SHAFT D704HO76.1 29 END BEARING D704H088.1 30 FEED SHAFT GEAR (D704H.057.4 at BOBBIN SHAFT Da4OsHO14.A 82 BOBBIN INTERLOCK D704H091.2 4 OPERATING SHAFT STEM ‘p704H097.1 35 RETAINER PIN 1704H1068.1 3B {EADSCREW NUT OPERATING SHAFT D704H089.1 37 LEADSCREW NUT ENGAGE SHAFT 704Hoe4.1 88 TRIP PLATE D704H094.1 89 LOCATION BUSH PIN 704H1008.1 40 CLUTCH Dz0sHOt 1 4“ WORMBOX SHAFT D70sHO12.1 a2 STUD 704H016.1 43 COLLAR D704HO17-1 44 SPACER D70sHo84.1 45, | TRIP WASHER D704H045.1 46 WASHER D704HO46.1 47 SPACER (D704H047.4 43 16T HELICAL GEAR D704H055.1 49 437 CLUTCH GEAR D704H056.1 50 WORM BOX CASTING 1D704H060.1 5t NUT DroaHoe4.t 82 ADJUSTER CAP D704H085.1 53 LOCATION BUSH CLIP 90aHo2s.1 54 IMPERIAL LEADSCREW NUT p704H067.1 55 LEFT HAND LEADSCREW SUPPORT D704H1069.1 66 METRIC LEADSCREW NUT 704H068.1 * | “TRUGH 10794 A704~ 00014 Page SlAPRON ASSEMBLY (2) 28 (18) (ie) (13) (27, 617) (120) 78 = ej) 5 (19) ©) (23 43) (49) (30) (43) (52)(48) (22) (24) (29) DOF 76, Page 5~iti 7R/GH 10/94 A704 — 0001 (A704 -0001A APRON ASSEMBLY TRIGH 10/04 A704 - 001A 87 RIGHT HAND LEADSCREW SUPPORT D704H070.1 58 INTERLOCK FINGER D704H087.1 53 INTERLOCK FINGER D704H091.4 60 LEADSCREW NUT FINGER D704HO08s.t 61 PIVOT PIN D704H090.1 62 ECCENTRIG PIN ‘D704H086.1 63 FRICTION PIN ‘7041093. 64 GASKET, GA - 0660 cy HEXAGON SOCKET BUTTON HEAD SCREW MBx12 FS - 0266 66 HEXAGON SOCKET CUP POINT SET SCREW M5xS FS-0490 6 HEXAGON SOCKET CUP POINT SET SCREW M6xS FS - 0496 68 4/8" BSPT PRESSURE PLUG PB - 0090 6 ‘Ve" BSPT PLUG PB-O170 70 3/8" BSP PLUG FESTO-3570 PB -0240 n IL WINDOW (7/8") DW4064A WA- 0010 rz BEARING FAGG2527 BG - 0280 73 WASHER Ms FORM C FP - 0030 4 COMPRESSION SPRING 8G 416 FR- 0105 7 HEXAGON SOCKET CAP HEAD SCREW M6x26 FS - 0138 76 HEXAGON SOGKET BUTTON HEAD SCREW MBx12 FS - 0286 7 HEXAGON SOCKET CUP POINT SET SCREW M4x4 FS - 0486 7a KNOB No, 8229 M10 THREAD HA - 0080 cr BALL STUD MB ‘YN - 0005 80 RIAD BALL JOINT INA GE1200 YN - 0015 at COMPRESSION SPRING SG 342 FR - 0003, 82 HEXAGON SOCKET BUTTON HEAD SCREW M5x8 FS - 0283 83 HEXAGON SOCKET DOG POINT SET SCREW M8x16 FS - 0386 84 KNOB (BLACK) HA - 0040 86 ‘O RING RMO136-24 ‘OA - 0070 a7 O-RING RMO216-24 OA- 0120 88 ADAPTOR ENOTS 26-0530-02 PA- 0050 89 ENOTS 36-0384 02K PA- 0185 80 BANJO BOLT ‘Dg04Hi039.1 a ‘4mm TUBE SLEEVE ENOTS 86-0501-02 PA= 0220 82 ‘mm TUBE NUT ENOTS 36-0500-02 PA- 020 94 4mm NYLON TUBE PF - 0010 95 INTERNAL CIRCLIP 1300x18 RA- 0270 96 STEEL BALL 5.0 DIA. UB - 0005 o7 STEEL BALL 7.0 DIA. UB - 0007 98 GLAGIER BUSH MB14200U BF - 0010 99 BALL DETENT SCREW SP1208 FS -0048 100 HEXAGON SOCKET DOG POINT SET SCREW Max12 FS - 0366 101 HEXAGON SOCKET COUNTERSUNK SCREW M10x25 FS- 0454 402 DOWEL PIN MSxi2 FT -0520 108 Mio HANDLE HA - 0160 104 WOODRUFF KEY 13x5x3 KA-0170 405 O RING RMO416-24 OA- 0280 4106 CONICAL DRIVE NIPP;LE OC - 0010 107 GLACIER BUSH MB1620DU. BF - 0120 108 HEXAGON SOCKET DOG POINT SET SCREW Méx12 FS - 0352 109 WOODRUFF KEY 6x0x22 KA- 0190 110 EXTERNAL CIRCLIP DIN1400/22 RA 0160 it ‘THRUST WASHER INA AS1520 BC - 0090 112 GLACIER BUSH MB1525DU BF - 0100 Page BivAPRON ASSEMBLY (3) LH. APRON, 68) @ Ril, APRON ( Page 5-v TR/GH 10/94 A704 - 000%A704 = 00014 APRON ASSEMBLY ‘TRIGH 10/04 A704 001A 413 | COMPRESSION SPRING SG 947 FR-0008 414 | BLACK KNOB HA 0040 418 | & CIRCLIP DIN 150012 FA -0305 116 | STEEL BALL 6.0 DIA: UB - 0008 117 | NEEDLE ROLLER BEARING AK1528 BC -0080, 118 | THRUST WASHER AS1528 BO - 0080 io | BUSH ‘B704H092.1 420 | GLACIER BUSH MB1525DU BF -0100 yt HEXAGON SOCKET DOG POINT SET SCREW Max16 FS -0368 {oo | NEEDLE ROLLER BEARING NTA-1625 BC - 0260, 429 | THRUST WASHER TRA-1625 BS - 0260 {3a | HEXAGON SOCKET DOG POINT SET SCREW MBxt0 FS-0790 428 | O-RING GRMOa96-24 ‘OA-0380 jae | Ol, SEAL25x35x7 0B-0180 130 | HEXAGON SOCKET NYLOCK DOG POINT SET SCREW M6x20 FS -0788 428 | SPIROL PINM4xa0 FT-0100 429 | ORINGGACO RMISI-16 ‘0A - 0080 131 HEXAGON SOCKET CAP HEAD SCREW Méxté FS-0194 43) | HEXAGON SOCKET FULL DOG POINT SET SCREW Méxt2 FS - 0952 133 | HEXAGON SOCKET CUP POINT SET SCREW Méx8 FS - 0498 {81 | HEXAGON SOCKET CUP POINT SET SCREW Méx10 FS - 0500 {35 | HEAGON SOCKET CUP POINT SET SCREW Mi0xi0 FS - 0524 197 NYLOGK FULL POINT SCREW M10x6 FS - 0809 49 | KNOB HANDLE KB6/1305 HA-0180 440, | ORING AMOS21-16 OA-0190 qat | THRUST RACE AXK1523 ‘BO- 0080 442 | THRUST WASHER AS1520 BG - 0090 443 | GLACIER BUSH MB1512DU BF - 0085 {44 | GLACIER BUSH MB2016DU BF -0130 445 | BALL BEARING 16003 BG - 0280 446 | WASHER FORM C MS FP - 0025 447_—_| - BRIGHT WASHER M5 FP 0030 14 | 84.420 SPRING FR: 0922 {ao | HEXAGON SOCKET CAP HEAD SCREW M3x10 FS- 0086 {0 | HEXAGON SOCKET CAP HEAD SCREW M5x12 FS- 0112 151 HEXAGON SOCKET CAP HEAD SCREW M5x20 FS-0116 jee | HEXAGON SOCKET CUP POINT SET SCREW M5x6 FS-0490 tga |. HEXAGON SOCKET CUP POINT SET SCREW.MBxS FS «0530 tg | PAN HEAD SLOTTED SCREW Méx10 FS +0704 485 | BRIGHT LOOK NUT MG FS - 0044 488 | SYMMONDS LOCK NUT MS FS - 0974 tg7__ | WOODRUFF KEY 6x7.6x19 KA- 0180 tea | HEXAGON SOCKET CAP HEAD SCREW M6x20 FS-0136 {eo | HEXAGON SOCKET CAP HEAD SCREW MBx20 FS-0162 460 |” ORING RM0036.24 OA 0008 161 HEXAGON SOCKET CUP POINT SET SCREW Méx40 FS- 0510 tee | HEXAGON SOCKET CUP POINT SET SCREW Maxé FS - 0489 163 | HEXAGON SOCKET CUP POINT SET SCREW Méxt2 FS- 0192 164 | COMPRESSION SPRING 84428 FR- 0310 4e6 | BANJO WASHER 48-0231-01 PA-0200 188 | OLIP 94-0218-02 PA- 0280 470 | FELT PLUG PB - 0070 Pago 64SADDLE ASSEMBLY (1) sy , Saye Snel = © GSE O0@ owian(a1) TR/GH 10/94 A119 — 0510 PageA119 - 05104 SADDLE AND CROSS SLIDE ASSEMBLY 1 BRACKET SUB ASSEMBLY A806 - O564A 2 PINION SUB ASSEMBLY ‘A834 - 00244, 8 KEEP SUB ASSEMBLY ‘A608 - 05824, 4 471 GEAR SUB ASSEMBLY ‘A806 - O566A 5 HAND WHEEL SUB ASSEMBLY ‘ABd2 - 00240, 8 ‘SADDLE HANDWHEEL KIT ‘A950 - 0015 12 SADDLE (GEARED HEAD MACHINE) D696 - 0056 13 CROSS SLIDE 705 - 0112 6 ‘SADDLE SCREW (METRIC) 897 - 0343 16 SADDLE SCREW (IMPERIAL) D597 - 0344 7 CROSS SLIDE NUT BODY 10388 - 0126 48 FIXED CROSS SLIDE NUT (METRIC) Da405H019.1 19 FIXED CROSS SLIDE NUT (IMPERIAL), D40sH020.1 20 ADJUSTABLE CROSS SLIDE NUT (METRIC) DaosHo2t.t at ADJUSTABLE CROSS SLIDE NUT (MPERIAL) DaosHo22.4 22 GROSS SLIDE NUT ADJUSTING SCREW ‘D40sH026.1 23 CROSS SLIDE INDEX RING (METRIC) Daag - 0198 25 CROSS SLIDE INDEX RING ((MPERIAL) 424-0195 26 COMPRESSION SPRING. 707-0024 a7 GROSS SLIDE THRUST PLATE D565 -0918 28 IDLER SHAFT | pee0- o7ae_| 80 ‘SWIVEL PEG 572-0023 at SPACER (D708 - 0251 a2 GIB ADJUSTING SCREW 1697 - 0345 3 ROSS SLIDE GIB STRIP (D345 - 0984 34 GRADUATION PLATE 537 - 1098 35 LOCK PAD B87 - 0144 38 SADDLE OIL FILLER PLUG 566-0194 37 FELT PAD 1/4"x1/2" D557 -0108 38 INDEX RING (METRIC) D424 - 0136 39 INDEX RING ((MPERIAL) Daza - 0198 50 SADDLE STRIP MOUNTING (D945 - 0083 Bt SADDLE STRIP D715 -0173 52 SHORT STRIP ADJUSTER D715 -0192 53 Lock PAD 557-0143 58 SADDLE CLAMP pris - 0172 et BED VEE WIPER (HEAD END) D997 #0011 62 BED VEE WIPER (TAIL END) D937 - 0012 63 BEDWAY VEE WIPER SHIELD 725-0014 64 LEAF SPRING D707 - 0051 Pago 6 ‘TRIGH 10194 A119-05108SADDLE ASSEMBLY (2) @®@ @©Q QDO@O®D OOO 602200 ® QOH 19) IMPERIAL, 48) METRIC TR/GH 10/94 Ali9 — 0510 Page 6~illA119 -0510A 65 BEDWAY FLAT WIPER oa7 - 0010 66 BEDWAY FLAT WIPER SHIELD D725 - 0013 67 WIPER SPRING 707 - 068 68 SPACER 708 - 0087 69 ESLOK SOCKET SET SCREW M6x6 Ds97 - 0869 70 ESLOK SOCKET SET SCREW MBx8 D897 - 0370 76 ‘THRUST BEARING AXZ.6.15.26.4, BC-0020 76 NEEDLE ROLLER BEARING AXK 2035 BC-0110 7 NEEDLE ROLLER BEARING AXK 1528 BC - 0080 78 ‘THRUST WASHER INA WS81104 8337 - 5014 79 ‘THRUST WASHER ASI520 BC -0090 et ll. SEAL W11007027 B44 - 9051 82 FIBRE WASHER, B4tt - 0020 84 CYCLE BALL BEARING 1/4" 8326 - 8107 85 CONCAVE LUBRICATOR 6mm ‘0c - 0010 8 'O' RING DOWTY 202-519 8413-0171 90 SQUARE KEY 18943 - 5008 92 ‘STEEL ROLLER 10x10 BD - 0080 93 SPIROLPIN Méxi6 FT-330 95, HEXAGON SOCKET BUTTON HEAD SCREW M4x12, FS -0278 96 HEXAGON SOCKET CAP HEAD SCREW M5x12_ F8-0112 7 HEXAGON SOCKET BUTTON HEAD SCREW Méx16 F8-0296 98 HEXAGON SOCKET SET SCREW W POINT M6x8 Biesy1561 99 HEXAGON SOCKET DOG HEAD SET SCREW M4x5: 163 - 1721 100 HEXAGON SOCKET CAP HEAD SCREW M6x20 FS -0136 101 HEXAGON SOCKET CAP HEAD SCREW M6x25 FS -0138 102 SLOTTED PAN HEAD SCREW MBxi6 FS +0723 403 | HEXAGON SOCKET CAP HEAD SCREW, WEDGLOK Mex25 FS - 0768 404 | HEXAGON SOCKET CAP HEAD SET SCREW MBx35 FS -0578 105 | HEXAGON SOCKET CAP HEAD SCREW Max6o FS -0178 306 | WEDGE LOK SET SCREW Mi2x20 Bie4 - 0170 107 DOG POINT SET SCREW Mi2x25 B13 - 1783 108 PLATED CAP HEAD SCREW M12x100 18163 - 1920 109 M2 PLATED WASHER. Bit7 - 0049 112 |. 8MMNYLON TUBE PF +0080 113 | NYLOC NUT Mi2 F8-0973 116 FIBRE WASHER1/2%3/4" Batt - 0016 117 | CRINKLE WASHER M6 FP - 0010 118 | WASHER MB FP -0050 Page 6-lv TRIGH 10194 A119-0510ASADDLE ASSEMBLY (3) Page 6- TR/GH 10/94 119-0100A119 - 05104 SADDLE AND CROSS SLIDE SUB - ASSEMBLY ‘TRIGH 10/94 A119-05108 era wEse BRACKET SUB-ASSEMBLY A806 - 0564 1 SADDLE SCREW BRACKET 050 - 0753 2 GLACIER BUSH MB16150U Batt - 1895 Pn PINION SUB-ASSEMBLY ‘A834 - 0024 1 CROSS SLIDE PINION 564-0105 2 PINION SHAFT EXTENSION 1Do08 - 0787 KEEP SUB-ASSENBLY ‘A806 - 0503, 2 GLACIER BUSH Mo25260U Batt - 1564 477 GEAR SUB-ASSEMBLY A806 - 0566 1 477 IDLER GEAR 344 - 1269 2 GLACIER BUSH MB12200U Batt - 1580 SADDLE HANDWHEEL KIT 8950-0015, 1 HANDWHEEL SUB ASSEMBLY ‘nada - 0024 4 CROSS SLIDE PINION WASHER D931 - 0344 5 COMPRESSION SPRING D707 - 0021 6 NEEDLE ROLLER BEARING (8357 - 5001 7 THRUST WASHER 12937 - 5002 8 CYCLE BALL BEARING 1/4” DIA. 3928 - 8107 9 SQUARE KEY 8349 - 5008, 10 HEXAGON SOCKET WEDGLOK CAP HEAD SCREW M&x25 B164 - 0054 HANDWHEEL SUB-ASSEMBLY ‘A082 “00244 1 HANDWHEEL 1983 - 0108 4 HANDLE see - 0188 7 SHIM WASHER 701 - 0034 10 SHOULDER SCREW 163 - 1968 Page ovTOPSLIDE ASSEMBLY @ @ g TR/GH 10/94 A125 — 0504 a <8, MOBY NO MBI avHOS oO Y-¥ NO NOWO3S dvuoS ee) iz,A125 - 0504A TOPSLIDE ASSEMBLY TRIGH 10/94 4126-05044 1 HAND WHEEL SUB ASSEMBLY ‘Ag#2 - 00250 2 KEEP SUB ASSSEMBLY ‘A806 - O584A 3 METRIC TOOLHOLDER BOLT 00s - 0453 8 METRIC INDEX RING Daze 0168 8 IMPERIAL INDEX RING D424 -0143 10 METRIC SCREW 697-0964 1 IMPERIAL SCREW D967 - 0365 2 METRIC NUT 596 - 0313, 13 IMPERIAL NUT 596-0314 4 SWIVEL SLIDE BOLT Doss - 0166 48 SWIVEL SLIDE 705-0113 18 SOLID TOPSLIDE 705-0115 7 SLOTTED TOPSLIDE 705-0116 19 TOOLHOLDER STUD 711-0190 2 ‘TOPSLIDE LOOK PAD 587-0145 22 iB STRIP 345 - 0085 23 GIB ADJUSTING SCREW 0897 - 0345 24 MULTI COMPRESSION SPRING 707 - 0024 2 LOCATION PIN 560 - 0298 26 6mm DIA. CONCAVE LUBRICATOR BAS4 - 2004 ar CYCLE BALL BEARING 1/4" DIA. 3926 - 8107 28 WOOODRUFF KEY 19x83 343 - 2002 32 HEXAGON SOOKET CAP HEAD SCREW" WEDGLOK* Moxt6 164-0037 33 HEXAGON SOCKET CAP HEAD SCREW Méx25 8169 - 0039 34 HEXAGON SOCKET BUTTON HEAD SCREW M6x20 Bi63- 1816, 35 HEXAGON SOCKET CUP POINT SET SCREW M12 B163 - 1594, 36 HEXAGON SOCKET DOG POINT SET SCREW Max20 B163 - 1754 38 WASHER Me 117 - 0009 39 WASHER M16 Bit7- 0018 ” NYLOC NUT Mt6 B147 - 9008, 43 WASHER M10 8117-0085 44 FULL NUT M10 Bi47-9154 HANDWHEEL SUB-ASSEMBLY —AB42~-0025A 1 HANDWHEEL, Desa - 0110 3 LONG HANDLE see - 0140 4 SHORT HANDLE 382 - 0141 KEEP SUB-ASSEMBLY A806 - 05848 1 KEEP. D442 - 0087 2 6mm DIA, LUBRICATOR B454- 2004 Pago 7: