Harbor Freight Tools 4019 User's Manual

MINI BENCH LATHE
Model 04019
ASSEMBLY AND OPERATING INSTRUCTIONS
®
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our Web site at: http://www.harborfreight.com
Copyright C 2003 by Harbor Freight Tools®. All rights reserved. No portion of this
manual or any artwork contained herein may be reproduced in any shape or form
without the express written consent of Harbor Freight Tools.
For technical questions, please call 1-800-444-3353.
PRODUCT SPECIFICATIONS
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SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures, parts list and assembly diagram. Keep your invoice with this manual. Write the invoice number
on the inside of the front cover. Keep this manual and invoice in a safe and dry
place for future reference.
GENERAL SAFETY WARNINGS AND PRECAUTIONS
1.
KEEP WORK AREA CLEAN AND DRY. Cluttered, damp, or wet work areas
invite injuries.
2.
KEEP CHILDREN AWAY FROM WORK AREA. Do not allow children to handle
this product.
3.
STORE IDLE EQUIPMENT. When not in use, tools and equipment should be
stored in a dry location to inhibit rust. Always lock up tools and equipment, and
keep out of reach of children.
4.
DO NOT USE THIS PRODUCT IF UNDER THE INFLUENCE OF ALCOHOL OR
DRUGS. Read warning labels on prescriptions to determine if your judgement or
reflexes are impaired while taking drugs. If there is any doubt, do not attempt to
use this product.
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PAGE 2
5.
USE EYE AND BREATHING PROTECTION. Wear ANSI approved safety impact
eye goffles and a full face shield when using this product. In work situations
where excessive dust is produced, use an ANSI approved dust mask or respirator. ANSI approved safety impact eye goggles, full face shield, dust mask, and
respirator are available from Harbor Freight Tools.
6.
DRESS SAFELY. Do not wear loose clothing, jewelry, or gloves as they can
become caught in moving parts. Wear a protective hair covering to prevent long
hair from becoming caught in moving parts. If wearing a long-sleeve shirt, roll
sleeves up above elbows.
7.
DO NOT OVERREACH. Keep proper footing and balance at all times to prevent
tripping, falling, back injury, etcetera.
8.
INDUSTRIAL APPLICATIONS MUST FOLLOW OSHA REQUIREMENTS.
9.
STAY ALERT. Watch what you are doing at all times. Use common sense. Do
not use this product when you are tired or distracted from the job at hand.
10.
CHECK FOR DAMAGED PARTS. Before using this product, carefully check that
it will operate properly and perform its intended function. Check for damaged
parts and any other conditions that may affect the operation of this product.
Replace or repair damaged or worn parts immediately.
11.
REPLACEMENT PARTS AND ACCESSORIES: When servicing, use only identical replacement parts. Only use accessories intended for use with this product.
Approved accessories are available from Harbor Freight Tools.
12.
MAINTAIN THIS PRODUCT WITH CARE. Keep this product clean and dry for
better and safer performance.
13.
MAINTENANCE: For your safety, service and maintenance should be performed
regularly by a qualified technician.
14.
USE THE RIGHT TOOL FOR THE JOB. Do not attempt to force a small tool or
attachment to do the work of a larger industrial tool. There are certain applications for which this tool was designed. It will do the job better and more safely at
the rate for which it was intended. Do not modify this tool, and do not use this
tool for a purpose for which it was not intended.
15.
WARNING: The warnings, precautions, and instructions discussed in this manual
cannot cover all possible conditions and situations that may occur. The operator
must understand that common sense and caution are factors, which cannot be
built into this product, but must be supplied by the operator.
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PAGE 3
SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS
1.
MAINTAIN A SAFE WORKING ENVIRONMENT. Keep the work area well lit.
Make sure there is adequate surrounding workspace. Always keep the work
area free of obstructions, sawdust, grease, oil, trash, and other debris. Do not
use the Mini Bench Lathe in areas near flammable chemicals, dusts, and vapors.
Do not use the Mini Bench Lathe in a damp or wet location.
2.
THE MINI BENCH LATHE IS FACTORY PRE-WIRED FOR 120 VOLT AC
USAGE. The Power Cord for this product is equipped with a 120 Volt AC,
2-Prong Plug. Never modify the Plug in any way. To comply with the National
Electric Code, and to provide additional protection from the risk of electrical
shock, this product should only be connected to a 120 Volt AC, electrical outlet
that is protected by a Ground Fault Circuit Interrupter (GFCI).
3.
DO NOT ABUSE THE POWER CORD. Do not use the Power Cord to pull its
Plug from an electrical power outlet. Keep the Power Cord away from heat, oil,
sharp edges, and moving parts. Route the Power Cord safely. Do not route the
Power Cord where it can be walked on or tripped over. Replace a damaged
Power Cord immediately.
4.
IF AN EXTENSION CORD (not included) IS USED, MAKE SURE TO USE
ONLY UL APPROVED CORDS HAVING THE CORRECT GAUGE AND
LENGTH . (See Figure A.)
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5.
REDUCE THE RISK OF ACCIDENTAL STARTING. Make sure the Power
Switch (part #2) is in the “OFF” position before plugging the Power Cord into a
grounded, 120 Volt AC, electrical outlet.
(See Figure B, and Assy. Diagram.)
6.
PRIOR TO STARTING THE MINI BENCH LATHE, MAKE SURE ALL ADJUSTING KEYS AND WRENCHES ARE REMOVED FROM THE TOOL.
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PAGE 4
7.
KEEP ALL SAFETY GUARDS IN PROPER WORKING ORDER, PROPER
ADJUSTMENT, AND PROPER ALIGNMENT.
8.
MAKE SURE THE WORKPIECE IS SECURELY MOUNTED IN THE MINI
BENCH LATHE BEFORE TURNING ON THE LATHE. An excessively loose
workpiece can fly off the Lathe, causing severe personal injury and/or property
damage.
9.
ALWAYS KEEP HANDS AND FINGERS AS FAR AWAY AS POSSIBLE FROM
THE MOVING PARTS OF THE MINI BENCH LATHE
10.
ALLOW THE WORKPIECE TO TURN UP TO FULL SPEED BEFORE FEEDING A TOOL BIT (not included) INTO THE WORKPIECE. When turning off the
Mini Bench Lathe, allow the Workpiece to slow down and stop on its own. Do not
press against the Workpiece to stop it.
11.
FEED THE TOOL BIT INTO THE WORKPIECE GRADUALLY. Do not force a
tool bit to remove material faster than it is designed to cut.
12.
NEVER ATTEMPT TO REMOVE MATERIAL STUCK IN THE MOVING PARTS
OF THE MINI BENCH LATHE WHILE IT IS PLUGGED IN AND RUNNING.
13.
NEVER STAND ON THE MINI BENCH LATHE. Serious injury could result if the
Mini Bench Lathe is tipped or if the moving parts of the Lathe are accidentally
contacted.
14.
ALWAYS TURN THE POWER SWITCH (part #2) TO ITS “OFF” POSITION
AND UNPLUG THE MINI BENCH LATHE FROM ITS ELECTRICAL OUTLET
BEFORE PERFORMING ANY INSPECTION, ADJUSTMENTS, MAINTENANCE, OR CLEANING PROCEDURES.
15.
WARNING: Some dust created by power sanding, sawing, grinding, drilling, and
other construction activities, contain chemicals known (to the State of California)
to cause cancer, birth defects or other reproductive harm. Some examples of
these chemicals are: lead from lead-based paints, crystalline silica from bricks
and cement or other masonry products, arsenic and chromium from chemically
treated lumber. Your risk from these exposures varies, depending on how often
you do this type of work. To reduce your exposure to these chemicals: work in a
well ventilated area, and work with approved safety equipment, such as those
dust masks that are specially designed to filter out microscopic particles.
(California Health & Safety Code 25249.5, et seq.)
16.
WARNING: People with pacemakers should consult their physician(s) before
using this product. Operation of electrical equipment in close proximity to a heart
pacemaker could cause interference or failure of the pacemaker.
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PAGE 5
UNPACKING
When unpacking, check to make sure all the parts shown on the Parts Lists on page 13
are included. If any parts are missing or broken, please call Harbor Freight Tools at the
number shown on the cover of this manual as soon as possible.
PRODUCT FEATURES
NOTE: For additional references to the parts listed in the following pages, refer to the
Assembly Diagram on page 14.
1.
The Lathe Bed (part #57) is made of cast iron and is T-ribbed, which ensures
rigidity and low vibration. The Headstock (part #14), Tailstock (part #45),
Carriage Assembly (part #35), and Lead Screw (part #58) are mounted on the
Lathe Bed. (See Figure B.)
2.
The 3-Jaw Chuck (part #67) is reversible, giving you larger capacity, and can be
used as either internal or external jaws. The workpiece is automatically centered
when held in the 3-Jaw Chuck. Workpieces with a diameter of up to 1” are
gripped with the internal jaws. Workpieces with a diameter of up to 2” are gripped
with the external jaws.
(See Figure B, and Figure D.)
3.
The Cover (part #1) is mounted on the left hand side of the Headstock (part #14)
and Lathe Bed (part #57). The Cover protects the Motor (part #12), Motor Pulley
(part #11), and Spindle Pulley (part #16). (See Figure B.)
4.
The Two Speed Motor Switch (part #66) allows the operator to run the Motor
(part #12) at either Low Speed (3,850 RPM) or High Speed (5,490 RPM). When
turning materials with a larger diameter, use the Low Speed setting. When
turning harder materials, use the Low Speed setting.
HEADSTOCK
(#14)
3-JAW CHUCK (#67)
TAILSTOCK
(#45)
COVER
(#1)
LEAD SCREW
(#58)
LATHE BED
(#57)
TWO SPEED
MOTOR SWITCH
(#66)
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FIGURE B
PAGE 6
5.
The Cross Slide (part #28) runs right and left along the Lathe Bed (part #57) and
can be locked in place using the Screw (part #29). A Hand Wheel (part #36) is
used to move the Cross Slide to the right (counterclockwise) and to the left
(clockwise) along the Lathe Bed. One complete turn of the Handwheel will move
the Cross Slide .065”. (See Figure C.)
6.
The Longitudinal Slide (part #35) is mounted above the Cross Slide (part #28)
and can be locked in place by tightening the Socket Screw (part #40). A Hand
Wheel (part #36) is used to move the Longitudinal Slide forward (clockwise) and
backward (counter clockwise). One complete turn of the Handwheel will move
the Longitudinal Slide forward or backward .065”. (See Figure C.)
7.
The Tool Holder (part #24) is mounted on top of the Longitudinal Slide (part #35)
and may be locked in position using the Socket Screw (part #26) and Nut
(part #27). (See Figure C, and Figure E.)
8.
The Tailstock (part #45) runs right and left along the Lathe Bed (part #57) and
can be locked in place using the Socket Screw (part #54). A Hand Wheel
(part #36) is used to move the Tailstock to the right (counterclockwise) and to
the left (clockwise) along the Lathe Bed. (See Figure C.)
9.
The Power Switch (part #2) is located next to the Two Speed Motor Switch
(part #66) and features power “ON” and power “OFF” selections.
(See Figure C.)
SOCKET SCREW (#26)
NUT (#27)
HAND
WHEEL
(#36)
TOOL CROSS
HOLDER SLIDE
(#28)
(#24)
TAILSTOCK
(#45)
SCREW
(#29)
HAND
WHEEL
(#36)
SOCKET SCREW
(#54)
LONGITUDINAL SLIDE
(#35)
FIGURE C
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SOCKET SCREW
(#40)
POWER SWITCH
(#2)
PAGE 7
HAND
WHEEL
(#36)
10.
The Lathe Spindle (part #23) turning speed is adjustable and allows the operator
to run the Spindle speed at either 130 RPM, 200 RPM, 350 RPM, 560 RPM,
920 RPM, 1,500 RPM, 2,450 RPM, AND 4,000 RPM. The correct speed depends on the diameter and hardness of the workpiece. The larger the workpiece,
the slower the speed. The harder the workpiece, the slower the speed.
(See Figure F.)
ASSEMBLY AND OPERATING INSTRUCTIONS
To Assemble The 3-Jaw Chuck For A Workpiece Up To 1” Diameter:
1.
Workpieces with a diameter of up to 1” should be gripped with the internal jaws
of the 3-Jaw Chuck (part #67). (See Figure D.)
2.
If necessary, reverse the jaws for internal gripping. To do so, unscrew, remove,
and clean each of the three jaws. Turn the knurled tension ring until the beginning of the spiral thread comes to the respective groove. (See Figure D.)
3.
The jaws are then inserted in the following order: (See Figure D.)
A. Jaw #1 is inserted in reverse in groove #1, then rotate the tension ring.
B. Jaw #2 is inserted in reverse in groove #2, then rotate the tension ring.
C. Jaw #3 is inserted in reverse in groove #3, then rotate the tension ring.
3
JAW
PIN
3
2
2
JAW
1
CAPACITY
UP TO
1
1”
JAW
PIN
FIGURE D
4.
3-JAW CHUCK
(#67)
WORKPIECE
Once the three jaws are securely attached to the 3-Jaw Chuck (part #67), center
the end of the workpiece within the three jaws. Insert the two Pins (included) in
the 3-Jaw Chuck, and securely tighten the jaws onto the workpiece.
CAUTION: Make sure to remove the two Pins from the 3-Jaw Chuck once
the jaws have been tightened.
(See Figure D.)
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PAGE 8
To Assemble The 3-Jaw Chuck For A Workpiece Up To 2” Diameter:
1.
Workpieces with a diameter of up to 2” should be gripped with the external jaws
of the 3-Jaw Chuck (part #67). (See Figure E.)
2.
If necessary, reverse the jaws for external gripping. To do so, unscrew, remove,
and clean each of the three jaws. Turn the knurled tension ring until the beginning of the spiral thread comes to the respective groove. (See Figure D.)
3.
The jaws are then inserted in the following order: (See Figure D.)
A. Jaw #1 is inserted in reverse in groove #3, then rotate the tension ring.
B. Jaw #2 is inserted in reverse in groove #2, then rotate the tenson ring.
C. Jaw #3 is inserted in in reverse in groove #1, then rotate the tension ring.
3-JAW CHUCK
(#67)
JAW
1
PIN
3
1
2
CAPACITY
UP TO
3
2”
2
JAW
JAW
PIN
FIGURE E
WORKPIECE
To Adjust The Tool Bit Center Height:
1.
The tip of the tool bit (not included) must coincide exactly with the center of the
Tailstock Center (part #50). If the tip of the tool bit is not positioned properly, the
correct cutting dimensions cannot be obtained. Also, the tip of the tool bit may be
damaged. (See Figure F, next page.)
2.
Place the tool bit in the Lathe’s Tool Holder (part #24), but do not yet tighten the
two Socket Screws (part #26) which clamp the tool bit in place. (See Figure F.)
3.
Have several small, thin, metal, shims (not included) on hand. (See Figure F.)
4.
Adjust the tip of the tool bit to the center of the Tailstock Center (part #50). If
necessary, insert the shim(s) under the tool bit in order to obtain the proper
centering. (See Figure F.)
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PAGE 9
5.
Once the centering procedure is completed, make sure to tighten the two Socket
Screws (part #26) to secure the tool bit in place. (See Figure F.)
IF NEEDED,
INSERT
SHIMS
(NOT INCLUDED)
HERE
SOCKET SCREW
(#26)
TIP OF TOOL BIT
(NOT INCLUDED)
TAILSTOCK ASSY.
(#45)
TAILSTOCK
CENTER
(#50)
TOOL HOLDER
(#24)
FIGURE F
To Adjust The Spindle Speed:
1.
CAUTION: Always turn the Power Switch (part #2) of its’ “OFF” position and
unplug the Mini Bench Lathe from its’ electrical outlet before performing
this procedure.
2.
The Mini Bench Lathe features three different Drive Belts: the Short Drive Belt,
the Medium Drive Belt, and the Long Drive Belt.
3.
The Short Drive Belt is mounted on the Idler (part #6) and the Motor Pulley
(part #11). Do not adjust or reposition this Drive Belt. (See Figure G.)
4.
The Medium and Long Drive Belts are accessory Belts, and both are used to
adjust the spindle speed of the Mini Bench Lathe. (See Figure G.)
FRONT VIEW
SIDE VIEW
SIDE VIEW
MOTOR PULLEY
(#11)
SHORT
DRIVE
BELT
IDLER
(#6)
MEDIUM
DRIVE
BELT
SPINDLE PULLEY
(#16)
A
FIGURE G
SKU 04019
LONG
DRIVE
BELT
B
A
A = OUTER BELT POSITION
B = INNER BELT POSITION
PAGE 10
B
5.
Open the Cover (part #1) to expose the Idler (part #6), Motor Pulley (part #11),
and Spindle Pulley (part #16). (See Figure B.)
6.
To adjust the spindle speed to run at 130 RPM and 200 RPM, place the
Medium Drive Belt on the outer (A) positions of the of the Idler (part #6) and
Spindle Pulley (part #16). For 130 RPM, set the Two Speed Motor Switch
(part #66)to its “LOW” speed setting. For 200 RPM, set the Two Speed Motor
Switch to its “HIGH” speed setting. (See Figures G, and B.)
7.
To adjust the spindle speed to run at 350 RPM and 560 RPM, place the
Medium Drive Belt on the inner (B) positions of the of the Idler (part #6) and
Spindle Pulley (part #16). For 350 RPM, set the Two Speed Motor Switch
(part #66)to its “LOW” speed setting. For 560 RPM, set the Two Speed Motor
Switch to its “HIGH” speed setting. (See Figures G, and B.)
8.
To adjust the spindle speed to run at 920 RPM and 1500 RPM, place the
Long Drive Belt on the outer (A) positions of the of the Motor Pulley (part #11)
and Spindle Pulley (part #16). For 920 RPM, set the Two Speed Motor Switch
(part #66)to its “LOW” speed setting. For 1500 RPM, set the Two Speed Motor
Switch to its “HIGH” speed setting. (See Figures G, and B.)
9.
To adjust the spindle speed to run at 2450 and 4000 RPM, place the
Long Drive Belt on the inner (B) positions of the of the Motor Pulley (part #11)
and Spindle Pulley (part #16). For 2450 RPM, set the Two Speed Motor Switch
(part #66) to its “LOW” speed setting. For 4000 RPM, set the Two Speed Motor
Switch to its “HIGH” speed setting. (See Figures G, and B.)
To Operate The Mini Bench Lathe:
1.
CAUTION: Make sure the Mini Bench Lathe’s Power Switch (part #2) is in
its “OFF” position, and the tool is unplugged from its grounded, 120 volt,
electrical outlet prior to performing the following steps.
2.
Depending on the diameter and hardness of the workpiece, use the Two Speed
Motor Switch (part #66) to select either the High Speed Motor setting (5,490
RPM) or Low Speed Motor setting (3,850 RPM).
3.
Depending on the diameter and hardness of the workpiece, remove the Cover
(part #1) and adjust the Spindle Belt (part #17) for the desired Spindle Speed
(130 RPM, 200 RPM, 350 RPM, 560 RPM, 920 RPM, 1,500 RPM, 2,450 RPM,
or 4,000 RPM). Then, make sure to replace the Cover.
4.
Center the tip of the tool bit (not included) to the tip of the Tailstock Center
(part #50). Use shims (not included) if necessary. Then, tighten the two Socket
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PAGE 11
Screws (part #26) to lock the tool bit in place.
5.
Assemble the three jaws of the 3-Jaw Chuck (part #67) accordingly (internal for a
workpiece up to 1” diameter - external for a workpiece up to 2” diameter).
Tighten the jaws onto the end of the workpiece to secure it in place. Then, make
sure to remove the two Pins used to tighten the jaws.
6.
Center the tip of the Tailstock Center (part #50) in the middle of the other end of
the workpiece. Make sure there is sufficient tension on the workpiece to keep it
securely in place. Then, tighten the Socket Screw (part #54) to lock the Tailstock
(part #45) in place.
7.
Move the Cross Slide (part #28) and Longitudinal Slide (part #35) to the initial
cutting position. Make sure the tool bit does not contact the workpiece.
8.
Plug the Mini Bench Lathe into the nearest grounded, 120 volt, electrical
outlet. Then, turn the Power Switch (part #2) to its “ON” position.
9.
Allow sufficient time for the workpiece to turn at full speed. Then, slowly and
carefully, use the Hand Wheels (part #36) to move the Cross Slide (part #28) and
Longitudinal Slide (part #35) in order to make the desired cuts on the workpiece.
10.
Do not force the Mini Bench Lathe or tool bit to remove material faster than they
are designed to cut. Make sure to feed the tool bit gradually into the workpiece.
11.
Once the turning job is completed, turn off the Mini Bench Lathe and wait until
the workpiece has stopped turning. Then, unplug the Mini Bench Lathe from its
electrical outlet.
INSPECTION, MAINTENANCE, AND CLEANING
1.
CAUTION: Always turn the Power Switch (part #2) to its “OFF” position and
unplug the Mini Bench Lathe from its grounded, 120 volt electrical outlet
before performing any inspection, adjustments, maintenance, or cleaning.
2.
BEFORE EACH USE, inspect the general condition of the Mini Bench Lathe.
Check for loose screws, misalignment or binding of moving parts, cracked or
broken parts, damaged electrical wiring, dull, cracked, or broken tool bit, and any
other condition that may affect the safe operation of the Mini Bench Lathe. If
abnormal noise or vibration occurs, have the problem corrected before further
use. Do not use damaged equipment.
3.
DAILY: With a soft brush, cloth, or vacuum, remove all debris from the Mini
Bench Lathe. Then, use a premium quality, lightweight machine oil to lubricate
all moving parts.
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PAGE 12
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY
DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR
DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER
THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE
IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTUER AND/
OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD
BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE
BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE
ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER
INSTALLATION OF REPLACEMENT PARTS THERETO.
PARTS LIST
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SKU 04019
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ASSEMBLY DIAGRAM
4
1
3
6
5
5
27
28
9
9
30
31
34
33
38
40
12
20
37
41
35
42
46
17
23
21
14
44
43
50
22
15
39
36
7
19
32
10
10
13
16
24
29
8
11
18
25
26
48
54
57
49
45
55
63
51
58
52
56
62
53
36
61
37
60
59
36 37
66
2
64
67: 3-JAW CHUCK NOT SHOWN
65
NOTE: Some parts are listed and shown for illustration purposes only, and are not
available individually as replacement parts.
SKU 04019
PAGE 14