UNITECH Co.

Troyan, Bulgaria

SERVICE MANUAL

Universal lathes

C404T, C404TM, C404TH

COPYRIGHT 2002 UNITECH BULGARIA

Universal lathes C404T. Service manual. Page 2

CONTENTS

1. GENERAL DATA ...............................................................................................................................................................5

1.1 MANUFACTURER AND EXPORTER .......................................................................................................................5
1.2 NAMEPLATE DATA ...................................................................................................................................................6
1.3 CERTIFICATE OF ACCEPTANCE .............................................................................................................................7
1.4 SPECIFICATIONS ..................................................................................................................................................... 11
1.5 APPLICATIONS ........................................................................................................................................................ 13
1.6 LATHE DESCRIPTION.............................................................................................................................................. 13
1.6.1 MAIN UNITS ....................................................................................................................................................... 15
1.6.1.1 GEAR BOX (0100) ...................................................................................................................................... 15
1.6.1.2 FEED BOX AND QUADRANT (0200 AND 0210) .................................................................................... 15
1.6.1.3 SADDLE BOX (0300 - FIG.1A) ................................................................................................................... 25
1.6.1.4 SADDLE ( BED AND CROSS, TOP SLIDES) 0400, 0410 - FIG. 1A .................................................... 26
1.6.1.5 LATHE BED (0500 - FIG. 1A) .................................................................................................................. 26
1.6.1.6 TAILSTOCK (0600 - FIG. 1A) .................................................................................................................. 26
1.6.1.7 COOLANT EQUIPMENT (FIG.6) .............................................................................................................. 27
1.6.2 CONTROLS ........................................................................................................................................................ 27
1.6.3 SAFETY DEVICES ............................................................................................................................................. 28
1.6.4 SIZES, WEIGHTS, VOLUMES ........................................................................................................................ 28
1.6.5 CIRCUIT DIAGRAMS ...................................................................................................................................... 30
1.6.5.1. ELECTRIC INSTALLATION ....................................................................................................................... 30
1.6.5.1.1. POWER SUPPLY REQUIREMENTS. .................................................................................................. 30
1.6.5.1.2. CONNECTING TO POWER SUPPLY. ................................................................................................. 30
1.6.5.1.3. OPERATION. ......................................................................................................................................... 30
1.6.5.1.4. PROTECTION. ....................................................................................................................................... 30
1.6.5.1.5. ZERO PROTECTION............................................................................................................................. 30
1.6.5.1.6. SERVICE AND MAINTENANCE. ....................................................................................................... 31
1.6.5.1.7. PERMISSIBLE HUMIDITY OF THE AIR............................................................................................ 31
1.6.5.1.8. PROTECTIVE DEVICES ADJUSTMENT AGAINST OVERLOAD .................................................. 31
1.6.6 SPECIAL FEATURES AND OPTIONAL DEVICES ........................................................................................ 32
1.6.6.1 TAPER TURNING ATTACHMENT ( FIG. 9) ............................................................................................. 32
1.6.6.2 SIX-POSITION TWO-DIRECTION LONGITUDINAL STOP (FIG. 10) ................................................. 32
1.6.6.3 NOISE MEASUREMENTS ....................................................................................................................... 33
1.7 USER’S ENVIRONMENT AND CONDITIONS ...................................................................................................... 35
1.7.1 WORKING PREMISES ...................................................................................................................................... 35
1.7.2 ENVIRONMENT ................................................................................................................................................ 36
1.7.2.1 HUMIDITY ................................................................................................................................................. 36
1.7.2.2 TEMPERATURE .......................................................................................................................................... 36
1.7.2.3 NOISE AND VIBRATIONS ....................................................................................................................... 36
1.7.3 FOUNDATION ................................................................................................................................................... 36
1.7.4 VOLTAGE SUPPLY ........................................................................................................................................... 37
1.7.5 POWER CONSUMPTION ................................................................................................................................ 37
1.7.6 PRODUCTS’ REMOVAL AND CLEANING .................................................................................................. 38
1.8 TRANSPORT, STORAGE, HANDLING .................................................................................................................... 39
1.8.1 TRANSPORT AND STORAGE .......................................................................................................................... 39
1.8.2 HANDLING ......................................................................................................................................................... 43
1.8.2.1 UNPACKING ................................................................................................................................................ 43
1.8.2.2 CLEANING .................................................................................................................................................. 43
1.8.2.3 ASSEMBLING ............................................................................................................................................. 44
1.8.3 LIFTING, LAYING, AFFIXING ......................................................................................................................... 44
1.8.3.1 LIFTING ....................................................................................................................................................... 44
1.8.3.2 LAYING AND AFFIXING .......................................................................................................................... 44
1.8.4 MOVING ............................................................................................................................................................. 45
1.8.4.1 DISMOUNTING .......................................................................................................................................... 45
1.8.4.2 PACKING ..................................................................................................................................................... 46
1.8.4.3 LOADING - SEE ITEM 1.8.1. .............................................................................................................. 46
1.9 LATHE OPERATION ............................................................................................................................................... 46
1.9.1 FIRST START ..................................................................................................................................................... 46
1.9.1.1 GEAR BOX START ..................................................................................................................................... 46
1.9.1.2 FEED BOX TEST (0200 - FIG. 1A) ........................................................................................................... 47
1.9.1.3 APRON BOX AND SADDLE TEST .......................................................................................................... 47
1.9.1.4 COOLANT EQUIPMENT TEST ................................................................................................................. 47
1.9.1.5 SAFETY DEVICES TEST ............................................................................................................................ 47
Universal lathes C404T. Service manual. Page 3

1.9.2 RECOMMENDABLE MATERIALS AND AUXILIARIES ................................................................................47

1.9.2.1 WORKING MATERIALS ............................................................................................................................47
1.9.3 ADJUSTMENTS .................................................................................................................................................48
1.9.4 PUTTING IN OPERATION ................................................................................................................................48
1.9.4.1 PRE-STARTING ACTIONS ........................................................................................................................48
1.9.4.2 LATHE START ............................................................................................................................................48
1.9.4.3 LATHE STOP ................................................................................................................................................48
1.9.4.3.1 NORMAL STOP .....................................................................................................................................48
1.9.5 OPERATION TYPES ..........................................................................................................................................48
1.9.6 SAFETY MEASURES FOR WORK WITH AUXILIARY DEVICES ..............................................................50
1.9.6.1 LOW SPEED. ..............................................................................................................................................50
1.9.6.2. MOVEMENT RESTRICTIONS ...................................................................................................................50
1.10. SERVICE AND MAINTENANCE ........................................................................................................................51
1.10.1 ADJUSTMENTS OF THE MAIN MECHANISMS : ......................................................................................51
1.10.1.1 GEAR BOX ................................................................................................................................................51
1.10.1.1.1 MULTIDISK CLUTCHES FOR FORWARD AND REVERSE ROTATION (FIG. 17) ...................51
1.10.1.1.2 BELT BRAKE (FIG. 18). ..................................................................................................................52
1.10.1.1.3 SPINDLE BEARINGS (FIG. 19)..........................................................................................................52
1.10.1.1.4 V-SHAPED BELTS .............................................................................................................................55
1.10.1.2 FEED BOX (FIG. 21) ................................................................................................................................56
1.10.1.3 LEAD SCREW (FIG. 22). .........................................................................................................................57
1.10.1.4 APRON BOX ..............................................................................................................................................57
1.10.1.5 SADDLE (BED AND CROSS SLIDE). ....................................................................................................60
1.10.1.6 SADDLE ( TOP SLIDE) - FIG. 25. .........................................................................................................62
1.10.1.7 TAILSTOCK - FIG. 26. ............................................................................................................................62
1.10.1.8 THREAD DIAL INDICATOR (FIG. 27) .................................................................................................63
1.10.2 MAINTENANCE ...............................................................................................................................................65
1.10.2.1 LUBRICATION SYSTEM (FIG. 28) .......................................................................................................65
1.11 LABOUR SAFETY PRECAUTIONS ........................................................................................................................68
1.11.1 PROTECTIVE ( SAFETY ) DEVICES ...............................................................................................................68
1.11.1.1. ON THE MECHANICAL SECTION ..........................................................................................................68
1.11.1.2. ON THE ELECTRICAL SECTION ............................................................................................................68
1.11.2 SAFETY DEVICES ACTION .............................................................................................................................68
1.11.3 REQUIREMENTS ON THE SAFE WORK WITH THE MACHINE ................................................................68
SPECIAL REQUIREMENTS AND ADDITIONAL RISKS .............................................................................................69
ENCLOSURES .......................................................................................................................................................................70
1.12. EQUIPMENT.............................................................................................................................................................70
Universal lathes C404T. Service manual. Page 4

This service manual contains all necessary information for safe transportation, storage,
handling, assembling, putting in operation, work and maintenance of lathes, produced by our company.
Here you will find helpful hints for solutions on every problem which may arise during your
work with the machine.
Observe rules and recommendations given you in this manual. It will guarantee durable,
accurate and safe operation of the machine.
In the event of a fault which can not be removed by yourselves, please, contact the Service
department of UNITECH or your exporter. The necessary addresses and names are given in this
manual or in your purchase contract.
Universal lathes C404T. Service manual. Page 5

1. GENERAL DATA

1.1 MANUFACTURER AND EXPORTER

Manufacturer :
UNITECH Co.
Bulgaria
5600 Troyan
Gen. Kartzov str. 229
tel. 0359/670 22107
fax 0359/670 22742

Exporter :
..............................................
..............................................
..............................................
..............................................
..............................................
Universal lathes C404T. Service manual. Page 6

1.2 NAMEPLATE DATA

Type : ...................................................
Distance between centres ...................................................
Metric / inch execution ...................................................
Electric supply .................V / ...........................Hz
Climatic execution :
- normal
- for humid tropical climate
Serial number .....................................................
Year of production .....................................................
Universal lathes C404T. Service manual. Page 7

1.3 CERTIFICATE OF ACCEPTANCE

The lathe meets the requirements of appropriate standards and is proved to be operable.

Date: ............................... Inspector : ....................................

/ /
Universal lathes C404T. Service manual. Page 8

Testing protocol

Type: ............................/............................ mm
Serial number: ...........................................

The lathe was tested according to BDS 2203-89 and DIN 8606 standards.

Tolerance
№ Object of test Limits [mm] Measured
BDS 2203 DIN 8606 [mm]
1 2 3 4 5
1 Machine straightening:
- longitudinal 0.016 for L up to 1500 O1 - 0.025
- crosswise 0.03 O1 - 0.04
2 Rectitude tolerance of longitudinal
saddle travel at horizontal plane:
- 750 to 1000 mm 0.010 G1- 0.020
- 1000 to 2000 mm 0.012 G1- 0.020-0.025
3 Parallelism of carriage movement
and tailstock guideways:
- horizontal plane 0.025 G2 - 0.03 for L  1500
0.04 for L > 1500
- vertical plane 0.016 G2 - 0.03 for L  1500
0.04 for L > 1500
4 Spindle axial run-out 0.006 G3 - 0.01
5 Accuracy of spindle travel at the 0.012 G3 - 0.02
nose plane
6 Radial run-out of external centering 0.008 G4 - 0.01
spindle taper
7 Radial run-out of internal spindle
taper:
- by the nose (point A) 0.006 G5 - 0.01
- at 300 mm (point B) 0.016 G5 - 0.02
8 Parallelism of spindle axis and
carriage travel:
- in horizontal plane 0.010 G6 - 0.015
- in vertical plane 0.020 G6 - 0.020
9 Parallelism of tailstock quill and
carriage travel:
- in horizontal plane 0.006 G7 - 0.015
- in vertical plane 0.020 G7 - 0.020
Universal lathes C404T. Service manual. Page 9

1 2 3 4 5
10 Parallelism of tailstock quill taper
and carriage travel:
- in horizontal plane 0.02 G8 - 0.03
- in vertical plane 0.02 G7 - 0.03
11 Tolerance between heights of 0.02 G9 - 0.04
spindle and tailstock quill axes with
respect to the guideways
12 Parallelism of spindle axis and top 0.016 G10 - 0.04
slide travel
13 Perpendicularity of spindle axis and 0.012 G11 - 0.02
cross slide travel
14 Lead screw axial run-out 0.008 G12 - 0.015
15 Lead screw pitch accuracy 0.025 (L=300) G13 - 0.004 (L=300)
16 Plain turning accuracy:
- non-roundness 0.008 P1 - 0.01
- non-cylindricity 0.02 P1 - 0.04 (L=300)
17 Face turning accuracy (machines 0.016 (d=300) P2 - 0.025 (d=300)
surface should be concave only)
18 Accuracy of threadcutting pitch 0.03 (L=300) P2 - 0.04 (L=300)

Warnning !
All tests must be performed after normal working temperature of gear box is reached. This temperature
should be about 40 degree higher then the ambient temperature.
Universal lathes C404T. Service manual. Page 10
Universal lathes C404T. Service manual. Page 11

1.4 SPECIFICATIONS

Parameters Dimensions Value

C404T C404TM C404TH
1 2 3 4 5
Main parameters

Height of centres mm 200 230 250

Distance between centres mm 750 750 750
1000 1000 1000
1500 1500 1500
2000 2000 2000
Width of guideways mm 320 320 320
Max. swing:
- over bed mm 415 475 515
- over cross slide mm 240 300 340
- bar capacity mm 50 50 50
- in gap mm 560 620 660
- in travelling steady mm 110 110 110
- in main fixed steady mm 140 140 140
Spindle
Spindle nose (DIN 55022) No. 6 6 6
Spindle bore mm 52 52 52
Spindle taper No. Morse 6 Morse 6 Morse 6
Front bearing diameter mm 80 80 80
Headstock
Number of speeds 12 12 12
Speeds ratio 1.41 1.41 1.41
Range of speeds rpm 45-2000 45-2000 45-2000
Drive
Main motor power kW 4/5.5 4/5.5 4/5.5
Main motor speed rpm 1450 1450 1450
Rapid traverse motor power kW 0.55 0.55 0.55
Rapid traverse motor speed rpm 950 950 950
Coolant pump motor power kW 0.18 0.18 0.18
Coolant pump motor speed rpm 2750 2750 2750
Power characteristics
Min. spindle speeds allowing full rpm 90 90 90
power transfer
Universal lathes C404T. Service manual. Page 12

1 2 3 4 5
Max. spindle torque at following
main motor powers:
- 4 kW Nm 380 380 380
- 5.5 kW Nm 530 530 530
Max. tractive force allowed by feed N 8000 8000 8000
mechanism
Feeds
Number of speeds 64 64 64
Range of longitudinal feeds mm/r 0.07-4.2 0.07-4.2 0.07-4.2
Longitudinal saddle speed - rapid mm/min. 2790 2790 2790
traverse
Crosswise saddle speed - rapid mm/min. 1130 1130 1130
traverse
“Cross/longitudinal feeds” ratio 1/2.5 1/2.5 1/2.5
Lead screw
Metric execution:
- diameter mm 40 40 40
- pitch mm 12 12 12
Inch execution:
- diameter mm 40 40 40
- pitch turn/1” 2 2 2
Threads
Number of threads 56 56 56
Range of threads:
- metric mm 0.5-30 0.5-30 0.5-30
- inch turn/1” 60-1 60-1 60-1
- module module 0.25-7.5 0.25-7.5 0.25-7.5
- D.P. DP 120-4 120-4 120-4
Saddle
Cross slide travel mm 255 255 255
Max. top slide travel mm 130 130 130
Max. pivot degree +/- 90 +/- 90 +/- 90
Tailstock
Quill diameter mm 60 60 60
Quill taper Morse No. 4 4 4
Max. quill travel mm 150 150 150
Lateral movement mm +/- 10 +/- 10 +/- 10
Universal lathes C404T. Service manual. Page 13

1 2 3 4 5
Toolposts
Four-position toolpost
- Max. tool cross-section mm 25/25 25/25 25/25
(height / width)
- Rotation degree 360 360 360

1.5 APPLICATIONS

This machine is applied for the following operations : surface turning, drilling, boring,
threadcutting, cutting, countersinking, reaming, etc. of workpieces of different shapes and sizes
(accepted by the lathe - see art. 1.4) and made of different materials as steel, cast iron, non-ferrous
metals and its alloys, plastic and wooden materials.
The table in art. 1.4 shows you the lathe capacity regarding feeds, threads, cutting force and
torques.
1.6 LATHE DESCRIPTION

The general view of the machine is presented on Fig. 1a. The seven main machine units are
marked by numbers 0100 - 0600 and the safe devices - by characters A, B, C and D.
Fig. 1b shows the lathe controls.

Main units:
- 0100 - gear box
- 0200 - feed box
- 0210 - quadrant
- 0300 - apron box
- 0400 - saddle ( bed and cross slide)
- 0410 - saddle ( top slide )
- 0500 - lathe bed
- 0600 - tailstock
- 0900 - coolant equipment
A. Quadrant cover with main motor emergency stop.
B. Chuck guard shield
C. Front safety screen

Controls
1. Handle for shifting screw rotation for left-hand or right-hand thread.
2. Handles for spindle speeds selection.
3. Push-button for normal ON of main motor.
4. Emergency stop button.
5. Flywheel for manual longitudinal saddle travel.
6. Handle for manual travel of cross slide.
7. Joystick for switching longitudinal or crosswise power feeds of the saddle.
8. Saddle locking bolt.
9. Handle for manual top slide travel.
10. Handle for quill locking.
11. Bolt for tightening the tailstock to the bed.
12. Screw for lateral tailstock travel.
13. Bolt for tailstock locking.
14. Flywheel for manual longitudinal quill travel.
Universal lathes C404T. Service manual. Page 14

fig. 1a

fig. 1b
Universal lathes C404T. Service manual. Page 15

15. Master switch.

16. Secret locks.
17. Control handle of the feed box multiplier.
18. Control handle of the feed box selector.
19. Joystick for switching thread type or power feeds.
20. Coolant equipment switch.
21. Oil distributor switch of the saddle.
22. Control handle of the lead screw semi-nut.
23. Multi-disc clutches switch ( for forward and reverse spindle rotation).
24. Saddle rapid traverse switch.
1.6.1 MAIN UNITS

1.6.1.1 GEAR BOX (0100)

The gear box unit contains mechanical clutches for forward and reverse spindle rotation, gear
drives providing 12 forward and 6 reverse spindle speeds and the spindle itself.
A desired spindle speed can be chosen by handles 2 ( Fig. 1a).

The spindle speeds are given in the table below:

C D
Range
1 2 3 1 2 3
A 45 90 180 355 710 1400
B 63 125 250 500 1000 2000

The exact path of transmission at different spindle speeds can be traced at the mechanical
diagram (Fig.2) and at the spindle speeds layout (Fig.3). The gear box shaft speeds in rpm are also
given on Fig.3.
Spindle switch in forward and reverse direction is controlled by handles (23 - Fig.1b) of the
control shaft by engaging the multi-disc clutches through a lever system. The clutches transfer motion
from the main motor to the gear box mechanism.

IMPORTANT! Spindle speeds switch is available when handle 23 has been shifted to neutral
! position, i.e. when the spindle is idle. Otherwise, there is a danger of gear stripping into the
headstock.

Main motor to gear box transmission is provided by four belts, mounted between two belt
pulleys (D1 and D2 - Fig.2). As far as the main motor speed at different current frequencies (50 or 60
Hz) changes, the belt pulleys diameters for 50 Hz or 60 Hz are different (see mechanical diagram -
Fig.2) in order to get always the same gear box shaft speed.
1.6.1.2 FEED BOX AND QUADRANT (0200 AND 0210)

These units are applied for providing different feeds and threads.
The quadrant is supplied with different sets of change gears depending on lathe execution. Fig.
4 represents quadrant arrangements for metric and inch execution of the lathe. Gear 60/2, drawn with
dash line, is mounted only on lathes with centres height 230 and 250 mm, i.e. on lathes TM and TH
types.
Universal lathes C404T. Service manual. Page 16

fig. 2
Universal lathes C404T. Service manual. Page 17

1420 min-1

1 60
80/
i 0=

/55

i2=47/47
39
i1 =
II

i 3=
0
5/7
i 5=2

55
/3
5

9
/5
39
i4 =
III
i7 =
1/84 88
i 6=2 /44

IV [min-1]
45

63

90

125

180

250

355

500

710

1000

1400

2000
Fig. 3

Two adjustments (first and second) of the quadrant should be done for metric and inch threads.
Special quadrants should be mounted for cutting inch threads 11.5 turns/1”, 19 turns/1” and 27
turns/1”.

IMPORTANT! Quadrants for cutting threads 11.5, 19 and 27 turns/1” are supplied upon
! special clients’ order.

The feed box contains multiplier, selector with specially adjusted gears and a mechanism for
thread type selection and transmission to the lead (feed) shaft, or to the lead (threadcutting) screw.
lathe).
Different sets of feeds or threads are available through appropriate adjustments of the quadrant and
through shifting handles 17, 18 and 19 in appropriate positions.
Handle 17 controls the multiplier and has four positions.
Handle 18 controls the selector and has eight positions.
Handle 19 controls the mechanism for thread type selection and transmission to the lead (feed)
shaft, or to the lead (threadcutting) screw, and has three positions.
The quadrant adjustments and appropriate positions of handles 17, 18 and 19 are given on
“Threads and feeds” nameplate, which can be found on the top of gear box and are shown on Fig. 5a
and 5b of this manual.
Universal lathes C404T. Service manual. Page 18

Metric execution of the machine

mm and TPI modul and DP 19 TPI

I setting II setting I setting II setting

Adjustement of feed box for:

24 TPI

Fig. 4a
Universal lathes C404T. Service manual. Page 19

Inch execution of the machine

mm and TPI modul and DPI 11.5 TPI 19 TPI 27 TPI

I setting II setting I setting II setting
42 42 42
42 88 33 69
56 56 56
56 64 56 64 54 (TM,TH) 54 (TM,TH) 54 (TM,TH)
54 (TM,TH) 80 (TM,TH) 54 (TM,TH) 80 (TM,TH)
80 80 80
115 114 108
80 54 80 54
120 69 120 69

Adjustement of feed box:

12 TPI 20 TPI 30 TPI

Fig. 4b
Universal lathes C404T. Service manual. Page 20

Fig. 5a - metric execution of the machine

Universal lathes C404T. Service manual. Page 21

/min 45 - 2000 45 - 355

I setting 1 2 3 4 5 6 7 8 II setting 1 2 3 4 5 6 7 8
42 A 0.5 0.562 0.625 0.687 0.750 0.812 0.875 0.937 88 4 4 1/2 5 5 1/2 6 6 1/2 7 7 1/2
R B 1 1.125 1.25 1.375 1.5 1.625 1.75 1.875 8 9 10 11 12 13 14 15
56 64
54 C 2 2.25 2.5 2.75 3 3.25 3.5 3.75 80 (TM,TH) 16 18 20 22 24 26 28 30
(TM,TH)
D 4 4.5 5 5.5 6 6.5 7 7.5 32 36 40 44 48 52 56 60
80 54
A 32 36 40 44 48 52 56 60 4 4 1/2 5 5 1/2 6 6 1/2 7 7 1/2
120 S B 16 18 20 22 24 26 28 30 69 2 2 1/4 2 1/2 2 3/4 3 3 1/4 3 1/2 3 3/4
C 8 9 10 11 12 13 14 15 1 1 1/8 1 1/4 1 3/8 1 1/2 1 5/8 1 3/4 1 7/8
D 4 4 1/2 5 5 1/2 6 6 1/2 7 7 1/2 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16
33 A 0.125 0.141 0.156 0.172 0.187 0.203 0.219 0.234 69 1 1.125 1.25 1.375 1.5 1.625 1.75 1.875
R B 0.25 0.281 0.312 0.344 0.375 0.406 0.437 0.469 2 2.25 2.5 2.75 3 3.25 3.5 3.75
56 64
54 C 0.5 0.562 0.625 0.687 0.75 0.812 0.875 0.937 80 4 4.5 5 5.5 6 6.5 7 7.5
(TM,TH) (TM,TH)
D 1 1.125 1.25 1.375 1.5 1.625 1.75 1.875 8 9 10 11 12 13 14 15
80 54
A 128 144 160 176 192 208 224 240 16 18 20 22 24 26 28 30
120 S B 64 72 80 88 96 104 112 120 69 8 9 10 11 12 13 14 15
C 32 36 40 44 48 52 56 60 4 4 1/2 5 5 1/2 6 6 1/2 7 7 1/2
D 16 18 20 22 24 26 28 30 2 2 1/4 2 1/2 2 3/4 3 3 1/4 3 1/2 3 3/4
42 A .0049 .0043 .0039 .0036 .0033 .0030 .0028 .0026 88 .0392 .0348 .0313 .0285 .0261 .0241 .0224 .0209
56 T B .0098 .0087 .0078 .0071 .0065 .0060 .0056 .0052 64 .0784 .0697 .0627 .0570 .0523 .0482 .0448 .0418
54 C .0196 .0174 .0157 0.142 .0130 .0120 .0112 .0104 80 (TM,TH) .1568 .1393 .1254 .1140 .1045 .0965 .0896 .0836
D .0392 .0348 .0313 .0285 .0261 .0241 .0224 .0209 54 .3136 .2787 .2508 .2280 .2090 .1930 .1792 .1672
80
A .0025 .0022 .0020 .0018 .0017 .0015 .0014 .0013 .0202 .0180 .0162 .0147 .0135 .0124 .0115 .0108
120 69
(TM,TH) T B .0050 .0045 .0040 .0037 .0034 .0031 .0029 .0027 .0404 .0359 .0323 .0294 .0269 .0249 .0231 .0215
C .0101 .0090 .0081 .0073 .0067 .0062 .0058 .0054 .0808 .0718 .0647 .0588 .0539 .0497 .0462 .0431
D .0202 .0180 .0162 .0147 .0135 .0124 .0115 .0108 .1617 .1437 .1293 .1176 .1078 .0995 .0924 .0862

Fig. 5b - inch execution of the machine

Universal lathes C404T. Service manual. Page 22

Formulas and examples for adjustments of different threads and feeds

To use these formulas and examples please take into account the cinematic paths of “ feed box
to threads and feeds” transmission (see Fig.2).
The motion for metric and module threads is transmitted from shaft VI through a pair of gears
from the multiplier to shaft IX through distributor muff to shaft X through a pair of gears in the
selector to shaft XI through distributor muff to shaft XII - lead screw.
The motion for inch and DP threads is transmitted from shaft VIII through a pair of gears in the
multiplier to shaft IX through the pair of gears 20/53 in the distributor to shaft XI through a pair of
gears in the selector to shaft X through the pair of gears 43/23 in distributor to shaft XII - lead screw.
The motion for power feeds is transmitted from shaft VIII through a pair of gears in the
multiplier to shaft XI through the pair of gears 20/53 in the distributor to shaft XI through a pair of
gears in the selector to shaft X through the clutch to shaft XIII - lead shaft.
When using the formulas below please take into account also the number of teeth of
appropriate gears included in the mechanical diagram on Fig.2, number of teeth of the change gears of
the quadrant (see Fig.4), as well as the lead screw pitch (12 mm for metric, or 12.7 mm for inch
execution of the machine).

Metric threads

Legend:
S - thread pitch, mm;
60
I1 - transmission ratio from the drive to gear box ( I r  );
90
Ir - transmission ratio
a
Ir  where a, b - teeth number of appropriate quadrant gears;
b
I2 - transmission ratio of the multiplier, as follows:

Handle 17 1/4 1/2 1/1 2/1

position (A) (B) (C) (D)
I2 16/64=1/4 27/54=1/2 40/40=1 36/18=2

I3 - transmission ration of the selector. For metric and module threads:

Handle 18 1 2 3 4 5 6 7 8
position
I3 26/39 27/36 30/36 33/36 36/36 39/36 42/36 40/32

t - lead screw pitch, mm.

Example: To cut metric thread with 0.5 mm pitch ( metric execution of the lathe) we read at the
“Threads and Feeds” name table:

Handle 17 is in position 1/4 (A), i.e. I2 = 1/4

Handle 18 is in position 1, i.e. I3 = 26/39,

Therefore:
Universal lathes C404T. Service manual. Page 23

60 24 1 26
S . . .12  0.5mm
90 64 4 39

For Inch threads:

25,4
W [ tpi ]
20 43
I1 .I r .I 2 . .I 3 . .t
53 23

Legend:

W - number of thread turns per 1” (tpi);

For inch and DP threads and for power feeds:

Handle 18 1 2 3 4 5 6 7 8
position
I3 39/26 36/27 36/30 36/33 36/36 36/39 36/42 32/40

Example: To cut inch thread W=3 1/2 tpi (metric execution of the lathe), we can read at the
“Threads and Feeds” nameplate (Fig.5):
51
Ir 
34

Handle 17 is in position 1/1 (C), i.e. I2 = 1/1

Handle 18 is in position 7, i.e. I3 = 36/42

Therefore, having in mind that:

20 43 25,4
. 
53 23 36

we have:
25,4 1
W  3 tpi
60 51 1 20 36 43 2
. . . . . .12
90 34 1 53 42 23

Module thread

1
m= . I1 . Ir . I2 . I3 . t [mm]


Legend :
m - thread module.

Example: To cut module thread with module m = 1.5 mm ( metric execution of the lathe),
we read at “Threads and feeds” name plate (Fig.5a):
Universal lathes C404T. Service manual. Page 24

33
Ir 
56

Handle 17 is in position 1/1 (C), i.e. I2 = 1

Handle 18 is in position 5, i.e. I3 = 36/36 = 1.

Therefore,

1 60 33
m= . . . 1 . 1 . 12 = 1.5 mm.
 90 56

D.P. threads

25,4.
DP  [DP]
20 43
I1 .I r .I 2 . .I 3 . .t
53 23

Example : To cut D.P. thread DP = 28 ( metric execution of the lathe), we read at “Threads
and feeds” nameplate:

33
Ir 
56

Handle 17 is in position 1/1 (C), i.e. I2 = 1/1.

Handle 18 is in position 7, i.e. I3 = 36/42.
Therefore,

25,4.
DP   28 DP
60 33 1 20 36 43
. . . . . .12
90 56 1 53 42 23

Longitudinal feeds

20
S = I1 . Ir. I2 . . I3 . I4 . z . m . π [mm/rev]
53

Legend:
S - feed value [ mm/rev];
I4 - transmission ratio for longitudinal power feeds of the apron box;

14 24 30 15
I4  . . .  0,04
25 30 66 76

z = 12 - Number of rack gear teeth of the apron box;

m = 2.5 - Module of rack gear teeth of the apron box.
Universal lathes C404T. Service manual. Page 25

Example: For feeds S = 0.35 mm/rev ( metric execution of the lathe ), we read at “Threads and
feeds” nameplate (Fig.5a) :

24
Ir 
64

Handle 17 is in position 1/1 (C), i.e. I2 = 1

Handle 18 is in position 5, i.e. I3 = 36/36 = 1

Therefore,

60 24 20
S= . .1. . 1 . 0.04 . 12 . 2.5 .  = 0.35 mm/rev.
90 64 53

Crosswise feeds

20
S = I1 . Ir . I2 . . I3 . I5 . t [mm/rev]
53

Legend:

I5 - transmission ratio of crosswise power feeds of the apron box;

14 24 30 17
I5  . . .  0,38
25 30 43 14

t - cross slide screw pitch;

t = 4 mm for metric execution of the lathe;
t = 5 turns/1” = 25.4/5 mm for inch execution.

Example: For feeds S = 0.570 mm/rev ( metric execution of the lathe ) we read in “Threads
and Feeds” nameplate (Fig. 5a):

51
Ir 
34

Handle 17 is in position 1/1 (C), i.e. I2 = 1/1.

Handle 18 is in position 5, i.e. I3 = 36/36 = 1.

Therefore,

60 51 20
S = . . 1 . . 0,38 . 4 = 0,570 mm/rev
90 34 53

1.6.1.3 SADDLE BOX (0300 - FIG.1A)

The main function of the saddle box is to receive motion from the feed box through the lead
screw and shaft and to transmit it through a system of gears and mechanical clutches of the saddle with
the toolpost being fixed on it. The lead shaft provides longitudinal and crosswise feeds of the saddle.
Universal lathes C404T. Service manual. Page 26

The feed values are shown on tables 5a or 5b. The lead screw provides all types of threads. The lathes
with D.B.C 1500 and 2000 mm are usually equipped with rapid traverse device of the lead screw. This
device contains rapid traverse motor, mounted in a cavity at the right side of the bed, chain drive for
transmission from the motor to lead shaft XIII and override clutch, mounted at the front end of the
shaft which is adjacent to the feed box.

IMPORTANT ! The direction of rapid traverse motor rotation is synchronized with the
direction of override clutch free rotation and of the rotation of main motor. For this reason,
! prior to the machine start, be sure that the direction of main motor rotation corresponds to the
arrow painted on belt pulley D2 (Fig. 2). After that you may test rapid traverse.
The standard equipment of machines with DBC 750 mm and 1000 mm does not include rapid
traverse device, unless being specially ordered by a client.

To ensure easy manual travel of the saddle in both direction, handle for power feeds switching (pos.7
on Fig. 1b), as well as handle 22, engaging the nut to lead screw, should be in neutral position.
1.6.1.4 SADDLE ( BED AND CROSS, TOP SLIDES) 0400, 0410 - FIG. 1A

The main function of the bed and cross slides 0400 is to receive the rotary motion from the
saddle box and to transmit it into lateral travel of the tool. This is provided by a pair of gears, one
being located in the apron box and another - cut on the cross feed screw, and transmission “screw -
nut”. The another important function of this unit is a precise guiding of the tool over the bedways in
longitudinal direction.
The top slide 0410 is fixed in a special round guide, grooved in the cross slide, providing its
rotation by +/- 90 degree. This way the top slide can be positioned at different angular locations with
regard to both longitudinal and crosswise travel directions and provides machining of short taper
forms.
The strokes of bed and cross slides and a top slide are 255 mm and 135 mm correspondingly.
The tool is locked in a special toolpost available in two options:
- quick-change DBU-W (multiflex type) , or
- universal four-position.

The both toolposts can be rotated by 360 degree.

1.6.1.5 LATHE BED (0500 - FIG. 1A)

The bed provides guiding of the saddle along its bedways and, together with the gear box,
absorbs the main efforts during operation. It is mounted over two or three (for DBC 2000 mm) legs.
The gear box, feed box, tailstock , saddle and fixed steady are mounted on the bed.
The bedways are hardened (HRc 40 - 44) and ground and provide wear resistance and working
accuracy of the lathe, as well as easy travel of the saddle.
1.6.1.6 TAILSTOCK (0600 - FIG. 1A)

The tailstock is mounted on the bed over two independent guideways (prismatic and flat).
A tailstock barrel (quill) with precise hole Dia.60 is located in the tailstock body. The quill
travel is driven by a flywheel at the rear side of tailstock. The flywheel transmits motion to the screw
with stub thread 24x5 (for metric execution of the lathe ), or 24x5 tpi (for inch execution of the lathe).
Longitudinal traverse of the quill is 150 mm.
The quill nose has a taper hole Morse No.4, in which cutting tool or live centre ( for machining
between centres) can be fixed. The height of quill taper axis corresponds to the height of spindle axis.
The saddle can be moved in lateral direction up to +/- 10 mm, providing turning small tapers
between centres.
Universal lathes C404T. Service manual. Page 27

1.6.1.7 COOLANT EQUIPMENT (FIG.6)

Coolant liquid is fed by electric pump. It is sucked from coolant tank 2 and supplied through
hose 3 to flexible pipeline, mounted on the saddle. Coolant flow is adjusted by tap 4. From bath 5 the
coolant liquid returns directly to tank 2.
Two-position switch (pos.20, Fig.1b) for coolant pump is located on the control panel.

IMPORTANT ! After using the coolant equipment, all unpainted metal machine parts should
! be cleaned and lubricated.

Use coolant liquids that do not corrode metal parts of the machine.
If the installation fails to supply coolant or the flow is dropped down, find and remove the
reason of the fault. The usual reasons are:
1) Reduction of coolant volume in tank 2 due to operation losses or leakage;
2) Installation plugging due to irregular cleaning and coolant changes.
For regular and faultless use of the coolant equipment clean it at least once in six months.

fig. 6

1.6.2 CONTROLS

1. Handle for shifting screw rotation for switching left-hand or right-hand thread. This handle
changes the screw rotation by reversing the rotation of output shaft of the gear box. In this situation,
the left-hand spindle rotation corresponds to the saddle traverse towards it, i.e. the cut thread is a left-
hand.

3. Push-button for normal start of main motor

Push this button to actuate main motor ( the master switch in the electric cabinet must be
switched on).
Universal lathes C404T. Service manual. Page 28

IMPORTANT! The main motor can not start when any of the safety devices is actuated, i.e.
! when the quadrant cover A is opened.

4. Emergency stop / normal stop button

This feature is used when is needed normal stop of the machine.

23. Multi-disc clutches switch ( for forward and reverse spindle rotation)

The handles have three positions :

- mid (neutral) position - spindle is static;
- down position - right-hand spindle rotation;
- up position - left-hand spindle rotation.

To stop the spindle, handles 23 should be shifted to neutral position. This engages the
mechanical brake built in the gear box. The stop-time of the spindle is 1 .... 4 sec., depending on the
spindle speed.

24. Rapid traverse switch.

For rapid (idle) traverse of the saddle in longitudinal and crosswise directions, firstly the
handle 7 should be shifted to a desired direction and then the rapid traverse push-button should be
switched.

IMPORTANT ! This button is not a self-locking and when you release it the rapid traverse
! motor will stop.

1.6.3 SAFETY DEVICES

QUADRANT COVER (A - Fig.1a) consists of a frame, fixed firmly to the lathe body, and a
cover providing access to the quadrants and belts for transmission to the gear box.
The cover is supplied with a safety interlock (switch), which is actuated by opening the cover
and initiates emergency stop of the main motor.

SAFETY SHIELD OF THE CHUCK (B - Fig.1a) is available for protection the operator from
accidental contact with the chuck during the machine work.

FRONT PROTECTIVE SCREEN (C - Fig. 1a) is provided for chips- and coolant protection
of the operator.

1.6.4 SIZES, WEIGHTS, VOLUMES

Overall dimensions and weights for different types machines are given on Fig. 7.
Universal lathes C404T. Service manual. Page 29

fig. 7
Universal lathes C404T. Service manual. Page 30

1.6.5 CIRCUIT DIAGRAMS

1.6.5.1. ELECTRIC INSTALLATION

The lathe is equipped with a main motor, rapid traverse and coolant pump motors (when these
additional accessories are ordered), electric panel, local lighting, electric controls and connecting
cables. The electric installation is performed for power of the main motor of 4 kW, at voltage and
frequency of the mains according to the customer’s requirements. All the motors are 3 period,
asynchronous, with a short circuit rotor. Controlling and local lighting circuits are fed by a distributing
transformer at voltages 24 V and 12 V AC, respectively.
The principle diagram of the electric installation for different types of the machine is given in
fig. 8.1 and 8.2.
1.6.5.1.1. POWER SUPPLY REQUIREMENTS.

For the normal work of the machine it is necessary the mains parameters to response to the
following maximum deviations from the rated values:
- voltage - +10% to до - 15%;
- frequency - ±1%
1.6.5.1.2. CONNECTING TO POWER SUPPLY.

The way the machine is connected to power supply is described in 1.7.5 (Voltage supply). The
presence of a four or five wire cabling is required. It is necessary when a four wire cable is used, the
neutral line N to be connected to PE.
1.6.5.1.3. OPERATION.

1) Supplying power and operating voltages.

When the machine is fed, it is necessary to check if all protections (QF0 to QF5) are on. Then
close the electric cabinet and switch on the master.
2) Main motor starting.
Starting of the main motor M1 is performed at fulfilled requirements in p.1) by pressing the
green button SА1, located on the control panel.
3) Shutdown of the main motor.
It is done under any of the following circumstances:
- S1 or SQ contacts are open (any of the safety devices has been activated);
- button SB has been pressed;
- absence of operating voltage (protection activated or power supply failure).
4) Switching ON/OFF coolant pump motor M2.
Switching on is performed by turning the switch SA2 clockwise, which is on the control panel.
Switching off is performed by turning the switch SA2 counterclockwise.
5) Switching ON/OFF rapid traverse motor M3.
Switching on is performed by pressing the button SA3, which is located on the apron. The
button is non-self -locking and when released, the motor stops. The rest of conditions are the same as
those concerning coolant pump motor.
7) Switching ON local lighting.
It is performed through the switch SA4 located on the lamp HME.
1.6.5.1.4. PROTECTION.

The electric installation is protected against shortcuts and continuous unallowable overloading
by means of the automatic circuit breakers QS - QF5.
1.6.5.1.5. ZERO PROTECTION.
Universal lathes C404T. Service manual. Page 31

When a descent or failure of power supply causes an automatic shutdown of the motors, they
remain off even power supply is restored, till their switching on again from the control panel.
1.6.5.1.6. SERVICE AND MAINTENANCE.

Safe work with the machine requires a periodical survey to grounding (zeroing) according to
the standards in strength.
! The electric motors should be cleaned periodically from dust and other impurities.
Power of work area lamp should not exceed 40 W.
1.6.5.1.7. PERMISSIBLE HUMIDITY OF THE AIR

The electric installation operates faultlessly in the range of relative humidity of the air between
30% and 95%.
1.6.5.1.8. PROTECTIVE DEVICES ADJUSTMENT AGAINST OVERLOAD

QS -
QF1 - 8.6 A
QF2 - 0.8 A
QF3 - 1.8 A
QF4 -
QF5 -

fig. 8.1
Universal lathes C404T. Service manual. Page 32

fig. 8.2

1.6.6 SPECIAL FEATURES AND OPTIONAL DEVICES

1.6.6.1 TAPER TURNING ATTACHMENT ( FIG. 9)

The device is applied for machining taper surfaces.

A special slide (1 - Fig.9) can be adjusted to angular position up to +/- 12 degree with respect
to the longitudinal direction of the saddle travel. Arm (2) is sliding along the guideways ( when the
taper turning attachment is idle) or is fixed to them when TTA is in use.
The arm (2) is coupled to the slide (1) and, being fixed to the guideways and the saddle being
moved in longitudinal direction, depending to the angular adjustment of the slide (1), the cross slide is
pushed out (being fixed to it) in lateral direction without using flywheel 3 for manual rotation of the
cross slide screw.
Max. length of taper pieces that can be machined with the taper turning attachment is 400 mm.
To get back a normal machining mode the slide (1) should be readjusted to O degree and the
arm (2) should be released.

1.6.6.2 SIX-POSITION TWO-DIRECTION LONGITUDINAL STOP (FIG. 10)

This device is used to set limits for longitudinal travel of the saddle in 6 different points. That
will provide the same lengths of piecework necks at volume production so that the operator should not
set the longitudinal travel (stroke) for each detail.
A special device, mounted in the apron box (1), switches off the gear muffs and
correspondingly - saddle feeds through the cams 2, that are moved and fixed on shaft 4 at precisely
Universal lathes C404T. Service manual. Page 33

defined by the operator position . The cams press a click, mounted in the apron box, which on its turn

fig. 9

cuts out the box mechanism and stops the saddle. The mechanism can be switched on again by a slight
movement of the saddle by flywheel 5 outside the cams, lifting and releasing lever 3 and, finally, by
shifting handle 6 to neutral position and to position corresponding to the desired direction of saddle
movement consecutively.
The accuracy of saddle positioning (limit) by using the six position longitudinal stop is 0,1 mm.

1.6.6.3 NOISE MEASUREMENTS

Noise level emitted by the machine was measured by special measuring devices : sound-level
meter “B&K” 2203, microphone "B&K" 4145.
The measurements were accomplished in accordance with DIN 45635, part 1601
"Measurement of airborne noise emitted by machines. Enveloping surface method. Metal working
machines. Lathes".
The lathe was placed on concrete base and levelled. The measurements were done for idle
running at max. speed, as well as for a normal machine work.
Universal lathes C404T. Service manual. Page 34

The maximum noise levels measured on the working space of the operator are given in the
following table:

idle run on load

Level of noise pressure on measuring surface Lp (A) in dB 82.8 75.1
Level of noise power Lw (A) in dB 99.4 91.7
Level of noise pressure on working place Lp (A) in dB 84.4 78.5
Value of measuring surface Ls in Db 16.6
Universal lathes C404T. Service manual. Page 35

fig. 10

1.7 USER’S ENVIRONMENT AND CONDITIONS

1.7.1 WORKING PREMISES

The machine has no special requirements to the premises where it would be mounted. The
place should be indoors (closed) and to meet the following requirements:
Universal lathes C404T. Service manual. Page 36

1) The floor should not be dirty and slipping in order to avoid accidents during work;
2) To have enough space for easy maintenance and service manipulations. The size of this
space as well as the operator's location are shown on Fig. 11.

Area of servicing
500
1000
800

OPERATOR

DBC (mm) 750 1000 1500 2000

A (mm) 3000 3300 3800 4300

fig. 11

1.7.2 ENVIRONMENT

1.7.2.1 HUMIDITY

The electric components of the lathe are especially sensitive to humility parameters. For this
reason :

IMPORTANT ! 1) The lathe which is not executed for work in tropical humid climate
! ( see item 1.2 of this manual) should not be used in such conditions.
2) After a long transportation period all motors and electric elements of the machine should
be properly tested and dried before the first start.

1.7.2.2 TEMPERATURE

For normal machine operation the temperature should not be higher then + 40 C degree.
1.7.2.3 NOISE AND VIBRATIONS

The noise and vibration levels of the working room should not be too high due to increased
possibility of operator’s errors ( subjective or due to accuracy reduction of the machine).
1.7.3 FOUNDATION

For more accurate work and long life of the lathe it should be established on a foundation and
Universal lathes C404T. Service manual. Page 37

precisely levelled. The foundation is made of concrete of width at least 350 mm. (see foundation
layout on Fig. 12)

1.7.4 VOLTAGE SUPPLY

The machine is delivered to the user fully equipped, the electric and coolant installations being
ready to start work, except the following details:
- When the machine is being packed for transportation, coolant hose is usually disconnected
from the pump union (nipple);
After attaching the hose you need only to connect the machine to power supply through the
cable.
Please, observe the following rules before connecting the machine to power supply :

1) Check whether the electrical parameters of the machine comply with the power circuit
parameters.
2) Check the contacting surfaces of electrical units.
3) If the electric motors are wet ( due to storage in wet place, long transportation, etc.) , check
and restore their insulating resistance, if necessary. It should be at least 1 Mohm for all motors.
The same resistance value should have the grounding bolt and all parts of the machine being
under high voltage.
The resistance between the grounding bolt and every other machine part should not exceed 0.1
Ohm.
4) The cross-section of supplying cable must be at least 3x2.5 + 2.5 sq. mm. The cable must
be properly isolated and put into protective case. When entering the electric panel, the supplying cable
should pass through el. input, providing insulation level of the internal part of the panel with respect to
environment being IP54.
1.7.5 POWER CONSUMPTION

The machine is supplied with electric power. It is equipped with:

- main motor with power 3, 4 or 5.5 kW / 1500 rpm ;
- coolant electric motor 0.16 kW / 3000 rpm ;
- rapid traverse electric motor 0.55 kW / 1000 rpm ( for lathes DBC 750 and 1000
mm. - upon special order of the client, for DBC 1500 and 2000 mm - as normal equipment);
- electric panel ;
- lighting equipment ;
- cables.

IMPORTANT ! Values of voltage and frequency of the electric motors are ordered by the
! client !

All motors are three-phase, asynchronous squirrel-cage type. The control circuit is supplied
from isolating transformer with 24 V (12 V) voltage. The lighter supply voltage is 12 V or 24 V.
The total consumption of the machine is :

1) For lathes with rapid traverse:

- 3.72 kW / main motor 3 kW;
- 4.71 kW / main motor 4 kW;
- 6.21 kW / main motor 5.5 kW;
2) For lathes without rapid traverse :
- 3.16 kW / main motor 3 kW;
- 4.16 kW / main motor 4 kW;
Universal lathes C404T. Service manual. Page 38

- 5.66 kW / main motor 5.5 kW;

DBC
750 1000 1500 2000
SIZE, мм
A 840 1140 1640 2140
B 3000 3300 3800 4300
C - - - 100
D - - - 360
E - - - 300
F - - - 500
G - - - 920
H - - - 560

fig. 12

1.7.6 PRODUCTS’ REMOVAL AND CLEANING

As far as the machine is fed with workpieces manually, the machined details are also removed
and stacked by hand.
We recommend the ready-made details to be stacked in pallets and then removed to
warehouses by crane or other lifting means, as fork lifters or hoists.
Universal lathes C404T. Service manual. Page 39

Waist materials (chips) are collected in the tray under the machine body (Fig. 13), coolant
liquid being strained through a tray strainer.
After finishing work, the chips should be removed in a pallet and then thrown out in a special
place. It is desirable that the chips pallets to be supplied with additional tray for coolant residue, in
which coolant liquid can be collected and returned to the coolant tank.

fig. 13

1.8 TRANSPORT, STORAGE, HANDLING

1.8.1 TRANSPORT AND STORAGE

All kinds of vehicles may be used for the machine transportation. Nevertheless, the lathe
should be packed in special wooden case, or fixed on wooden skid and covered with polyethylene. In
both cases the machine is firmly locked to the case floor or skid with bolts. One part of the lathe
attachments is mounted on the lathe body, and the others are packed in a separate small case, fixed to
the floor.

The packed machine can be loaded into vehicle :

1) by crane, observing the hoisting ropes being tied as shown on scheme (Fig.14a and 14b).

IMPORTANT ! Do not stay under the hanging machine - danger of serious wounds.
!

2) by electric or diesel fork-lifter. In this case the forks have to grip the machine firmly at the
both sides of the main beam of case or skid. For the purpose the lifters must be fitted with fork
extensions providing a reliable fixing of 2/3 of the case (or grip) length.
Universal lathes C404T. Service manual. Page 40

fig. 14a
Universal lathes C404T. Service manual. Page 41
Universal lathes C404T. Service manual. Page 42

fig. 14b

fig. 15

! IMPORTANT ! Do not use hoisting mechanisms of load capacity being less that
the gross weight of the lathe.

The load capacity of hoist mechanisms used for the machine lifting must comply with the lathe
weight.
Observe the following rules during transportation:
Universal lathes C404T. Service manual. Page 43

To transport a single machine, load it in the middle of the vehicle and fix the skid at all sides
with wooden blocks 1, as shown on Fig. 15.
Those blocks protect the machine from lateral and longitudinal displacement during
transportation or from blowing the machine off the vehicle.
To transport several machines in one vehicle, spacing between the machines, or between the
machine and the vehicle walls, should be not more than 50 mm. Otherwise, the machines have to be
extra locked.

The machines storage may be done, as follows:

1) Compactly ordered one by one on a suitable stage;

IMPORTANT ! Being fixed on skids and covered with polyethylene, the machines must be
! stored indoor.

2) The machines may be stacked in two stacks.

IMPORTANT ! In this case the machine should be specially ordered to be packed in

! special reinforced cases.
IMPORTANT ! On delivery (before storing) the wooden cases or machines (if packed on
skids) should be checked and their “on-delivery” condition should be declared.

1.8.2 HANDLING

1.8.2.1 UNPACKING

Being delivered on skid, the lathe is covered with polyethylene, nailed to the skids with
wooden laths. To unpack it, do the following:
1) Unnail the laths and remove the polyethylene cover from the lathe. 2) Dismount the
bolts fixing the machine to the skid by unscrewing nuts and removing them out of the skid. The four
bolts are placed at the external side of the front and back legs of the lathe.
Being packed in wooden case, the machine have to be unpacked as follows:

1) Unnail and remove the case cover.

2) Unnail and remove the side and face walls of the case.

IMPORTANT ! All nails in the case parts must be extracted to avoid eventual wounding of
! the stuff. After that the case cover and walls may be stored.

When the machine is released from the case, proceed unpacking as described above.
1.8.2.2 CLEANING

We recommend the cleaning to be done after foundation or establishing the machine on the
working stage.
As far as the unpainted parts of the machine are greased, they should be cleaned in the
following succession:
1) All flywheels, handles, levers and other control elements.
2) The guideways : firstly from one side of the saddle, and then from the other side.
3) All slides, apron cover, spindle and gear box flange.
If you find grease stains on the painted parts of the lathe, do not remove them, or at least do it
Universal lathes C404T. Service manual. Page 44

with chemicals that would not hurt the varnish coating.

To clean the machine from grease, use only dissolvents that do not corrode metal parts. After
cleaning, the guideways should be slightly lubricated with oil, which will protect them from corrosion
and provide long life of the machine.

IMPORTANT ! Use only harmless for face and hands dissolvents and do not burn fire in the
! vicinity of inflammable substances.

1.8.2.3 ASSEMBLING

The machine is delivered to the client in condition ready to putting in operation, except the
following details:
1) Three-jaw universal chuck is dismounted and packed in the small case, and the chuck flange
is mounted on the spindle.
Upon client’s request the chuck may be fitted by the manufacturer and delivered in ready
condition. This delivery option is preferable because all necessary tests of the chuck accuracy will be
done in the factory and the manufacturer will guarantee it.
2) To prevent possible damages during transportation, the flywheels for longitudinal and
cross travel together with the dial are dismounted in the factory before packing. They are packed in the
small case. Their mounting is easy, when using the locking elements, i.e. special screw for cross travel
flywheel and a locking screw for long travel flywheel (after being mounted on the apron box shaft).
3) The coolant hose, being disconnected from the pump and packed in the tray for collecting
chips and coolant, should be coupled to the coolant pump.
1.8.3 LIFTING, LAYING, AFFIXING

1.8.3.1 LIFTING

The unpacked machine must be lifted only by means of a crane. Before lifting make the
following checks of the machine:
- whether the tailstock, steadies, saddle and other moving parts are properly fixed to the
machine body;
- lock the tailstock at the end of the body with its flywheel being aligned with the body edge;
- lock the fixed steady next to the tailstock and the saddle - as close as possible.
The machine is tied with hoisting rope or chain as shown on Fig. 16. Exactly, the row steel bars
with diameter 45 mm and length 1000 mm are inserted into special holes in the front and back legs of
the lathe.

IMPORTANT ! The hoisting ropes must be fitted with bushes and bolts that would
! prevent their slippage or extracting out of the lifting bars.

1.8.3.2 LAYING AND AFFIXING

The machine levelling is done in the following order :

- put steel levelling pads by each hole made for foundation bolts in the concrete foundation
slab;
- establish the lathe on the concrete slab. Observe that the levelling screws lay on the levelling
pads and the foundation bolts match with the holes in the slab
- do the first levelling of the lathe with levelling screws, using a high- precision level to
Universal lathes C404T. Service manual. Page 45

control horizontality of the guideways crosswise and longwise with respect to the machine axis. The
measuring accuracy is 0.004 / 1000 mm;
- After the first levelling fill the foundation holes and space under the machine feet with
concrete mix. “Concrete : sand” ratio = 1 : 3.
- After solidification of the concrete tighten evenly the foundation nuts;
- Check the machine levelling once again and, if necessary, readjust it with the foundation
bolts.
Being properly levelled, the machine accuracy is within the tolerances stated in the testing
certificate. The final check can be done after putting the lathe into operation. To achieve trouble-free
operation study carefully this manual.
After a long experience of work with these machines, the manufacturer states that they have
proved to preserve their accuracy and reliability without being established on special foundation. You
may take advantage of this if, for one or another reason, you need to move often your machinery to
different places. In this case, it’s enough the machine to be established on a firm base (for example, on
concrete floor) and be levelled, using the levelling pads and screws.
After the first machine foundation, the longwise and crosswise horizontality of the guideways
must be controlled and, if necessary, adjusted, at least once in three months.
If the lathe is not placed on special foundation, this check must be done even more frequently,
depending on the floor quality. Observance of this rule will guarantee you long life and good working
accuracy of your machine.
After the machine units having been cleaned and lubricated, and their operation having been
tested in manual mode, the machine may be connected to the power supply. To do it safely, read the
instructions regarding the electric installation.

fig. 16

1.8.4 MOVING

1.8.4.1 DISMOUNTING

1) Cut out the supply cable from the voltage;

2) Open the electric panel and disconnect the supply cable from the terminals;
Universal lathes C404T. Service manual. Page 46

3) Unscrew the foundation nuts and release levelling studs;

4) Release the nut, connecting the coolant hose to the pump, remove the coolant tank
cover , wrap it in paper and place in the chips-collecting tray;
5) Lift the machine by lifting bars, inserted in the holes in the front and back feet of
the lathe, place it on the wooden skis where it was placed before.
1.8.4.2 PACKING

1) After being placed on skid, the lathe is fixed by screwing the bolts, washers and nuts in the
special holes in the front and back feet of the machine.
2) All unpainted parts are greased with oil or special preserving grease depending on the
transportation and storage period and the place of destination. If the period of transportation and
storage is less than two weeks, there is no need to use the grease.
3) The lathe is covered with polyethylene and the cover is nailed to the skid.
4) To use wooden case the packing procedure is just the opposite to this described in item
1.8.2.
1.8.4.3 LOADING - SEE ITEM 1.8.1.

1.9 LATHE OPERATION

1.9.1 FIRST START

When the actions described in items 1.8.2, 1.7.3 and 1.7.5 of this manual are already done, you
may start the first putting in operation.

For the purpose do the following checks and actions:

1) Check the electrical connections to the supply circuit : voltage, protective and neutral
earthing;
2) Check the stretching of V-shaped belts and their tightening to the front foot the main motor
base plate;
3) Check whether all safety shields (screens) and quadrant cover are closed and whether the
multidisk clutches switching lever is in neutral position;
4) Fill oil to the gear, feed and apron boxes ( according to description given in items 1.6.4 and
fig. 28);
5) Switch on the master switch on the electric cabinet door;
6) Start the main motor on idle run;
At that moment the oil pump in the gear box should also start. You can state it by oil spray
ejected from the oil-pipe, located behind the upper oil-level indicator in the gear box.
If there is no such oil spray, the following fault may have happened :

The main motor rotates in wrong direction, i.e. on actuating clutches lever (pos. 23 in Fig. 1b),
the direction of spindle rotation does not conform with the corresponding direction indicated on the
label on the right side of the feed box. In this event transpose any two phases of the feeding cable.
1.9.1.1 GEAR BOX START

IMPORTANT ! During test of the gear and feed box, the apron box should not move to avoid a blow
into the left or right edge of the lathe body. For this purpose, handle 7 (Fig. 1b) must be
! switched in neutral position, and handle 22, engaging the nut to the lead screw, must be in
upper (OFF) position.
 Universal lathes C404T. Service manual. Page 47

The test is done for all spindle speeds, beginning from the lowest one (45 rpm) and finishing at
the highest one (2000 rpm). Take use of the nameplate for spindle speeds, mounted on the front of the
gear box.
The speeds should be shifted per 2 minutes up to 500 rpm and per 5 minutes from 500 till 2000
rpm. After reaching the highest speed, the gear box has to be working till it warms up to the constant
temperature. This temperature should be about 40 degree higher then the ambient temperature.
1.9.1.2 FEED BOX TEST (0200 - FIG. 1A)

The right and safe operation of the feed box mechanisms is checked by using handles 17, 18
and 19. When the handle 17 is shifted to power feeds, the lead screw is prevent from rotation

IMPORTANT ! All the handle (17, 18 and 19) could be shifted easily during the gear box work.
!
1.9.1.3 APRON BOX AND SADDLE TEST

Handles 7 and 22 (Fig. 1b) are used to fulfil the test. When they are in idle position, the saddle
is free for longitudinal travel through rotating flywheel 5, and for crosswise travel - through shifting
handle 6.
Interlock is provided to prevent the simultaneous operation of the both handles (7 and 22).
When the handle 7 has been switched to one of the four available directions, the saddle (
correspondingly the cross slide) is travelling in the same direction. When the handle 22 is switched on,
the saddle is moving left-hand or right-hand depending on the direction of the lead screw rotation.
If the lathe is supplied with rapid traverse device, it has to be tested also. Push the button 24
when handle 7 is being switched. The saddle should travel rapidly in the appropriate direction.
The long guideways and lead screw semi-nut are forced feed lubricated from a piston pump,
mounted in the apron box. The pump must be tested prior to putting the machine in operation. It is
built in the left wall of the box, the oil-distributor being controlled by handle 21, as shown on the name
plate, located under the pump.
The guideways and semi-nut are lubricated when the saddle is moving.
1.9.1.4 COOLANT EQUIPMENT TEST

Firstly fill the coolant tank with coolant according to the information about volumes, given in
item 1.6.4, and after that start testing.
Check whether the coolant hose (pos.3 - Fig. 6) is coupled to the pump and the flexible pipe,
feeding coolant to the tool or workpiece. Usually the hose is disconnected for transportation and
packed on the tray 5 (Fig. 6).
When the above checks are done, switch the two-position switch 20 (Fig. 1b). Coolant floor
may be adjusted through tap 4 (Fig. 6).
1.9.1.5 SAFETY DEVICES TEST

Testing of safety devices, protective attachments and emergency stop buttons should be done as
described in items 1.6.2 and 1.6.3 of this manual.
1.9.2 RECOMMENDABLE MATERIALS AND AUXILIARIES

1.9.2.1 WORKING MATERIALS

The main application of the machine is turning of workpieces made of metals and alloys, as
follows:
- all kinds of ferrous alloys: steels - normal, reinforced and alloyed; cast iron and others. Take
in consideration also the shape and type of cutting tool, used for the definite material;
- non-ferrous metals : copper, aluminium and their alloys;
Universal lathes C404T. Service manual. Page 48

- other materials that could not badly affect the health of the operation during machining.
The machining of wooden, plastic and other similar workpieces is not recommendable. Such
materials require using of additional ventilation and safety devices.
1.9.3 ADJUSTMENTS

The details are given in item 1.10.

1.9.4 PUTTING IN OPERATION

1.9.4.1 PRE-STARTING ACTIONS

Prior to putting the lathe in operation always do the following:

- check oil levels in the gear, feed and apron boxes;
- lubricate all points of the machine, required to be lubricated every eight hours according to
the Instruction for lubrication (Fig. 28);
- check the movement of the chuck jaws and clean it, if necessary;
- check coolant level in the tank (if the coolant equipment will be used);
- move manually the bed and cross slides and check the forced feed lubrication of the
guideways;
- switch on the main motor on idle run and check operation of the gear box pump;
- start spindle rotation and saddle travel on idle run and check operation of the rapid traverse
device (if available).
1.9.4.2 LATHE START

Start the machine, as follows :

- switch on the master switch (pos.15 - Fig.1b) - the green lamp, mounted at the side of the
electric cabinet, will light;
- check whether the levers (pos.23 - Fig. 1b) are in neutral position, and all safety shields
(screens) and covers are closed. Handle 22 should be switched off, and handle 7 - in neutral position;
- push the green button 3 at the control panel - the main motor will start;
- choose desired spindle speeds with the handles 2;
- shift the lever 23 in the desired direction, after being pulled out of the protecting groove.

IMPORTANT ! When the spindle is rotating, do not put your hand under the safety shield of
! the chuck. If you need to open it, use the knob, mounted on it.

The rapid traverse device can be used also, when the spindle is rotating (levers 23 engaged). Do
it through shifting the handle 7 to desired direction and pushing the button 24. Remember, that this
button is not a self-locking and its releasing will stop rapid traverse.
1.9.4.3 LATHE STOP

1.9.4.3.1 NORMAL STOP

The usual practice is to stop the spindle rotation and saddle travel during machining in order to
change the detail or cutting tool, or to shift spindle speeds and so on.
In these cases the main controls for normal stop are levers 23 (Fig. 1b). Being shifted to neutral
position, they stop the spindle and lead screw and shaft by engaging the brake in the gear box.
1.9.5 OPERATION TYPES

The machine is mainly applied for turning of metal details. The detail has a main rotary spin,
Universal lathes C404T. Service manual. Page 49

being clamped in the chuck or in other device (spindle taper hole, face plate, between centres), while
the tool has the main progressive motion, being fixed in the toolpost (lathe knife, cutting, boring or
threadcutting tool, etc.), or in the tailstock taper hole (drill, countersink drill, reamer, etc.)

1) Short workpieces machining in chuck.

The detail is clamped firmly in the chuck, mounted on the spindle nose. Depending on the
workpiece swing, choose the appropriate spindle speeds and saddle feeds, as well as the tool suitable
for machining the details of this shape and material.
The following operations can be done:
- straight turning;
- drilling and boring;
- face turning;
- cutting.

IMPORTANT ! Do not put your hand under the machined detail during cutting - danger of
! serious hurt or clothes bite.

2) Turning between centres or between chuck and live centre.

Long and small-diameter workpieces should not be clamped only in chuck, as they may be
deformed during machining or the spindle may be bent. Long and heavy details may be blown off the
chuck and cause bad accident.
Such details have to be machined either between centres ( the dead one in the spindle and the
live one - in the tailstock), or clamped in chuck and supported by the live centre.
For such type of machining the details should be prepared by drilling a suitable center holes in
their faces ( the hole diameter should correspond to the diameter of detail).
The following operations can be done:
- straight turning of cylindrical surfaces;
- cutting of external threads;
- taper turning.
To turn tapers the following preparations should be done::
a) the top slide is rotated at the desired angular position and is fed manually by the handle
(pos.9 - Fig 1b);
b) The tailstock is moved in lateral direction through the screw (pos.12 - Fig. 1b).
This way the taper can be machines all over the workpiece length.

IMPORTANT ! The above types of machining can be done only between centres.
IMPORTANT ! To turn between centres, or between chuck and live centre, the tailstock
! should be firmly locked to the guideways through nuts 11 (Fig. 1b). When the live centre
catch the detail, its quill should be locked through handle 10.

3) Drilling.
Usually the drill is locked in the taper hole of tailstock quill, or in chuck, fixed in the same
place. The feeds are fulfilled as follows:
a) through knob 14 (Fig. 1b) of the tailstock - when the length of drilling hole is less then the
quill stroke (150 mm). In this case the tailstock is fixed firmly to the guideways by means of nuts 11;
b) through tailstock feeds - in this case the tailstock is coupled to the saddle with special
strips, mounted on the rear part of the saddle and the front part of the tailstock, attached slightly to the
guideways and moved forward together with the saddle. During this operation the tailstock quill
should be locked through knob 10.
Countersinking and reaming operation can be done as described above.
Universal lathes C404T. Service manual. Page 50

4) Turning of extremely long details.

This operation is done between centres, or between chuck and live centre, by using the fixed
and travelling steadies.
The both steadies can also be used separately, depending on the workpiece swing.
The machining of large-diameter high-density details can be done with or without live centre,
the detail being fixed in the fixed steady. The three steady quills should be aligned to precise guide of
the rear part of workpiece, while the front part of it being fixed in the spindle chuck. If the workpiece
is too dense, it may be additionally fixed by the live centre.
To machine long workpieces of small diameters the travelling steady must be used for
additional support of details. The steady is mounted over the saddle and travels together with it,
supporting the workpiece from the back in the cutting zone. This way the detail is provided from
distortion and dimensional errors.
The both steadies could be delivered both with standard (friction), or roller, quill.
5) Threadcutting
This operation can be done in two ways:
a) by turning with a special turning knife (for external threads), or by a tap ( for internal
threads). Depending on the thread pitch, the appropriate feeds are chosen and the threadcutting is
executed through engaging the saddle nut to the lead screw by means of knob 22 (Fig. 1b) and
selection of the thread type and pitch through handles 17, 18 and 19. Selection of right-hand and left-
hand threads is done through handle 1.

IMPORTANT ! This way of threadcutting requires special skills and can be worked only by
! experienced operator.

b) by threadcutting tool. The tool (tap or die) is clamped in chuck, mounted in the taper hole
of the tailstock, and is fed to the workpiece through the tailstock quill. The tailstock should not be
locked to the guideways in this case, otherwise the thread may break or the tool hurt.
6) Asymmetrical details turning.
This is done by means of the four-jaw independent chuck through shifted clamp, the detail
being displaced with respect to the rotating center, or by means of the jawless face plate, as the details
are clamped to any required place through the clamping strips, being displaced from the rotating
centre.
In the same way different rotary shapes - as forks, cams, eccentrics, etc., can be turned on the
non-cylindrical details.
1.9.6 SAFETY MEASURES FOR WORK WITH AUXILIARY DEVICES

1.9.6.1 LOW SPEED.

When using four-jaw independent chuck or jawless face plate observe the maximum speeds,
given on the special nameplate over their noses.

! IMPORTANT !
Do not exceed the allowed speeds - serious danger of accident.

1.9.6.2. MOVEMENT RESTRICTIONS

A. Taper turning attachment.

TTA has two restrictions of the movement:

1) Taper surface, machined with TTA, can not be longer then 400 mm;
Universal lathes C404T. Service manual. Page 51

2) The total length of the workpiece is limited by arm 1 (Fig. 8) and the driving bar, the total
longitudinal travel of the saddle is decreased when the taper turning attachment is used. To use the
whole machining length dismount the arm 2.

IMPORTANT ! Observe the above restrictions - otherwise the taper turning attachment
! can be destroyed.

B. Effort limits for longwise and crosswise feeds.

A special clutch (0300 - Fig. 1a) built-in the apron box is fitted for disengaging the saddle
when the feed force exceeds 800 N for longitudinal or crosswise travel.

IMPORTANT ! Do not readjust the safety clutch. If you have to do it, measure the switching
!
effort with dynamometer. Its value must not exceed 8000 N.

1.10. SERVICE AND MAINTENANCE

All mechanisms of the lathe are adjusted and tested at the factory. As a result of friction
between the moving parts during long period of the machine operation, run-outs may arise and
additional readjustments may be need. The readjustment of some mechanisms should be done also
after repairs.

IMPORTANT ! To begin adjustment or repair, firstly switch off the master switch of the
! machine and provide it against accidental start - for example, by locking or appropriate
warning label.

1.10.1 ADJUSTMENTS OF THE MAIN MECHANISMS :

1.10.1.1 GEAR BOX

1.10.1.1.1 MULTIDISK CLUTCHES FOR FORWARD AND REVERSE

ROTATION (FIG. 17)
Universal lathes C404T. Service manual. Page 52

fig. 17

When the discs get worn, the arisen run-out should be adjusted, as follows:
- unscrew the bolts and remove the gear box cover;

! IMPORTANT ! Check that the master switch is switched off and properly protected.

- pull plate 1 together with the lock pin 2 out of the slot of nut 3 and rotate them 90 degree;
- screw the nut 3 till the excessive run-out between the discs is removed. Check that the levers
23 (Fig.1b) for switching forward or reverse spindle rotation does not block in working position;
- shift the plate 1 in the initial position and slightly rotate the nut 3 till the lock pin 2 enters the
nearest hole of the disc 4. Now the nut 3 is provided against self- loosening and the clutch is adjusted;
- put the cover on the gear box and screw the bolts.
Properly adjusted clutch transmits the full power from the main power without the disc
slippage.
Do not forget to check whether the clutch is not worming up in idle position.
1.10.1.1.2 BELT BRAKE (FIG. 18).

If the spindle can’t stop in 4 - 5 seconds after disengaging the clutch, the belt brake needs to be
readjusted.
The belt brake adjustment is done, as follows:
- switch off the master switch and protect it against accidental start;
- unscrew the bolts and remove the gear box cover;
- unscrew the check nut 1 (Fig. 18);
- disengage the clutch by shifting the lever 23 (Fig. 1b) in neutral position;
- screw the nut 2 till excessive run-out between the bolt 3 and drum 4 is removed;
- tighten the check nut 1, supporting by hand the nut 2;
- put the cover on the gear box and tighten the bolts.
If the belt 3 is worn out , replace it with a new one.
1.10.1.1.3 SPINDLE BEARINGS (FIG. 19)
Universal lathes C404T. Service manual. Page 53

1) Front bearing.
The radial run-out of the front radial double-raw roller bearing (SKF - NN3016K P5) is
adjusted at the factory. Normal working conditions provide the bearing against wearing for a long
period of the machine operation.
If you need to replace the bearing 2, the radial run-out is adjusted, as follows:
- dismount the spindle;
- stuff the external ring of new bearing 2 into the gear box hole. The ring opening should be
measures with tolerance up to 0.001 mm;
- mount the internal ring of the bearing 2 together with the rollers on the spindle without
placing the spacer ring 1. By means of nut 4 the bearing is stuffed on the spindle taper till the internal
diameter of the roller ring is measured to be 0.002 - 0.003 mm less than the external diameter of the
bearing 2;
- measure the distance “d” between the spindle nose A and the front of the internal ring of the
bearing 2 with tolerance up to 0.002 mm;
- reface the front of the spacer ring 1 till the ring width is measured to be equal to the distance
“d” with tolerance up to 0.005 mm;
- dismount nut 4 and bearing 2 from the spindle;
- the spindle unit should be assembled entirely in the gear box. By means of nut 4 tighten
firmly the bearings 2 and 3 to the ring 1 and the spindle nose A;
- lock the nut 4 through a copper pad and lock screw.
Universal lathes C404T. Service manual. Page 54

fig. 18
Universal lathes C404T. Service manual. Page 55

fig. 19

Now the bearing 2 run-out is adjusted.

Radial-axial bearing 3 is never adjusted. It should only be tightened axially by means of nut 4.
When the above actions have been done, make control check of the whole unit by switching the
spindle at 2000 rpm speed for 30 min. The temperature of the unit should not reach more than 40 C
degree over the ambient temperature.

2) Rear bearing.
The radial run-out of the rear radial double-raw roller bearing 5 (SKF - NN 3013K) is adjusted
in the same way as for the bearing 2.

Remark: We recommend the dismounting and assembling of the spindle unit to be done by
specialists, trained to work with the bearings FAG and SKF.
For a front support variant with two taper roller bearings (see lower side of the front support, fig.19),
bearing 9 is tightened axially to the thrust flange by means of nut 4, until optimum preliminary
tightening is obtained (approximate axial clearance of the spindle must be 0.01 mm). It is checked by
turning the spindle by hand (the turning should be light but without clearance) and the heating of the
bearing until at high revolutions is observed: it must not exceed 40º above the ambient temperature for
30 minutes.
The radial clearance of the back radial double-row roller bearing (3013K) is adjusted in the same
way as bearing 2.
1.10.1.1.4 V-SHAPED BELTS

These belts need to be stretched after a period of the machine being in use, or after their replacement.

1) Belts stretching.

IMPORTANT ! Check that the master switch is switched off and properly protected.
!

- remove the side cover at the lathe leg under the gear box;
- loosen the bolts (4 pcs.), supporting the base plate 2 (Fig.20);
- release screw 3 till the belts are stretched so, that under the pressing force 140 - 145 N they
do not give in more than 20 - 25 mm;
Universal lathes C404T. Service manual. Page 56

- tighten the bolts of the base plate 2 and close the side cover.

2) Belts replacement - if there are broken fibres even only on one belt, the whole set of V-
shaped belts must be replaced

! IMPORTANT ! Check that the master switch is switched off and properly protected.

- remove the side cover under the gear box;

- loosen the bolts (4 pcs.), supporting the base plate 2 (Fig. 20);
- tighten screw 3 at maximum to release the belts;
- change the belts. Begin replacement from the upper (larger) belt pulley and mounting new
belts - in the reverse succession.

! IMPORTANT ! Danger of fingers bite.

- loosen the screw 3 till the desired stretching is achieved;

- tighten the bolts of the base plate 2 and close the side cover.
Pay attention the grease from the change gears not to get on the belts.
1.10.1.2 FEED BOX (FIG. 21)

If you have removed the feed box cover for repair, mount it in the following succession:
- mount the gears as shown on Fig. 21;
- shift the handles 20, 21 and 22 in the following positions:
- handle 20 - in position 1/1 (C);
- handle 21 - in position 1;
- handle 22 - in power feed position (T);

fig. 20

- grease the cover with sealant and return to its place;

 Universal lathes C404T. Service manual. Page 57

- stuff the both dowel pins and tighten the bolts.

IMPORTANT ! Turn off the master switch!

!

1.10.1.3 LEAD SCREW (FIG. 22).

On overloading the lead screw, the safety pin is sheared and cuts out the power circuit.
Replacement of the safety pin should be done, as follows:
- unscrew the plug;
- align the holes of the bush and screw;
- knock out the broken shift;
- replace it with a new one from your spares kit;
- put the plug.

! IMPORTANT ! Turn off the master switch!

1.10.1.4 APRON BOX

1) Safety mechanism (Fig. 23).

Switching force of the safety mechanism can be adjusted, as follows:
- switch off the lathe and unscrew plug 7;
- tighten screw 1, which will press the spring 2;
- test the safe mechanism ( for example, up to the longitudinal stop, or locked tailstock). The
apron box should stop smoothly, without backlash;
- screw the plug 7.
Universal lathes C404T. Service manual. Page 58

fig. 21

IMPORTANT ! Tightening of the spring 2 through the screw 1 should be done

! step-by-step , being tested frequently, till the desired result is achieved.
Universal lathes C404T. Service manual. Page 59

If the safety mechanism is disengaged, you can switch it on by shifting handle 3 in neutral
position. The safety clutch should be restored, otherwise, the apron box needs to be dismounted. To do
it:
- remove the apron cover;
- switch the safety clutch by hand;
- shift handle 3 in neutral position;
- unscrew lock nut 6;
- play between the head of screw 4 and that of screw 5 is adjusted by unscrewing screw 4, so
that the play to be within 0.2 - 0.5 mm
- lock the screw 4 with nut 6;
- mount the apron cover.

fig. 22
Universal lathes C404T. Service manual. Page 60

fig. 23

IMPORTANT ! As far as the whole mechanism would be removed together with the cover,
! this operation have to be done by a qualified service technician.

2) Six-position longitudinal stop.

1.10.1.5 SADDLE (BED AND CROSS SLIDE).

1) Cross screw and nut (Fig. 24).

The run-out between the cross screw and nut is adjusted, as follows:
- remove the cap 3;
- press the pins 2 inside;
- screw the nut 1 till normal run-out is achieved without tightening;
- release the pins 2 and observe that one of them has locked the nut 1;
- place the cap 3.
Universal lathes C404T. Service manual. Page 61

IMPORTANT ! Do not forget to protect the machine against accidental start - for example,
! by switching the master switch off.

2) Cross screw adjustment (Fig.24).

Axial run-out of the cross screw running is adjusted as follows:
- release screw 9;
- remove washer 8;
- unscrew nut 1 by half-turn;
- screw nut 6 till obtaining a minimum run-out without tightening the bearing 10;
- screw nut 7;
- put the washer 8 and fix it with screw 9.

IMPORTANT ! Do not forget to protect the machine against accidental start - for example,
! by switching the master switch off.

3) Bed slide (Fig. 24).

Clearance between the bedways and the bed slide is adjusted, as follows:
- measure the clearance space with clearance gauge;
- release and remove the screw 12;
- plane A of the plate 13 is reduced according to the measured clearance;
- place and tighten screw 12;
- unscrew check nut 14;
- screw bolt 15 till the clearance between the plate 16 and the bottom surface of the rear
guideway is removed;
- tighten the check nut 14.
Check that the saddle movement is not tight.

4) Cross slide dove tail.

The dove tail run-out is adjusted through two screws, as follows:
- release slightly screw 2;
- tighten the both screws 1 and 2 simultaneously till obtaining desired clearance;
- tighten the screw 2.
Universal lathes C404T. Service manual. Page 62

fig. 24

1.10.1.6 SADDLE ( TOP SLIDE) - FIG. 25.

1) Screw and nut.

The run-out between screw and nut of the top slide is adjusted as described in item 1.10.1.1.8,
part 1).
2) Dove tail.

fig. 25

The dove tail run-out is adjusted as described in item 1.10.1.5, part 4).
1.10.1.7 TAILSTOCK - FIG. 26.

Lateral displacement of the tailstock 1 with respect to the pad 2 is done, as follows:
- release the both nuts 3;
- release bolt 4;
- by tightening the screw 5 the tailstock is displaced inside, and by unscrewing it - in the
opposite direction. The displacement is controlled by scale 6.
- tighten the bolt 4 and nut 3.

IMPORTANT ! The scale 6 is not precise, and to match the tailstock axis with the spindle
! one, more precise measuring devices should be used.
Universal lathes C404T. Service manual. Page 63

fig. 26

1.10.1.8 THREAD DIAL INDICATOR (FIG. 27)

The thread dial indicator is an optional device, delivered upon special order. It is applied for
easier cutting of long threads with many runs. Its adjustment is limited to engagement of the gear 3 to
the lead screw 8. To do it loosen the screw 1, turn the case 2 till engaging the screw and tighten the
screw 1. It is a must to check whether when the nut is engaged to the lead screw, and the dial - to the
screw, and whether one of the notches of the dial 5 matches with the arrow 7. The dial 5 receives
rotary motion through shaft 4 and gear 3. Digits 1,2,7 of the name plate 6 correspond to the 14-teeth
gear. Digits 1,3,5 correspond to the 15-teeth gear. To cut threads with appropriate pitch turn the dial 5
and gear unit 3.
Universal lathes C404T. Service manual. Page 64

To cut inch threads use the appropriate dial (with one-side scale) and the 16-teeth gear.

EXAMPLE : Cutting thread with 0,5 mm pitch.

Digit 1 of the dial 6 corresponds to the desired pitch. To cut this thread, the dial 5 is not rotated
and one of its notches ( digit 1 in this example) stands against the arrow 7. After the first run the
operator removes the knife, disengage the slit nut, returns the saddle to the initial position by rapid
traverse and stop it when the digit 1 comes against the arrow 7. Than the slit nut is engaged, the tool
being provided to match with the pitch. Repeat the procedure till the thread is cut.

IMPORTANT ! The thread dial indicator is fitted on the lathes without firm (permanent)
! protection of the lead screw and shaft, and must be specially ordered by the client.
Universal lathes C404T. Service manual. Page 65

fig. 27
1.10.2 MAINTENANCE

1.10.2.1 LUBRICATION SYSTEM (FIG. 28)

Prior to the first start of the lathe, the gear box and other mechanisms should be lubricated.
The gear box is forced feed lubricated from the gear pump. The oil pump is fixed to the shaft of
the clutch and driven by it. The box is filled with oil up to the middle of the lower oil level indicator
(pos.6 - Fig. 28). The oil pump feeds oil through the filter and injects it into the oil distributor. One
part of the oil is refined by the fine filter and is splashing up to the upper oil level indicator. If the oil
Universal lathes C404T. Service manual. Page 66

can not reach the upper indicator, the machine should be immediately stopped and the fault removed.
If the pump does not work properly at the first machine start, the usual reason is the reversed
rotation of the main motor. The belt pulley in the gear box must be rotating in the counter-clockwise
direction.
The oil in the gear box should be changed according to the scheme, given on Fig. 28 and table
1. The waste oil is poured out through the plug under the quadrant cover, the box is washed out with
pure gas oil, and the new oil is filtered before filling the gear box.
The quadrant is greased periodically according to Fig. 28.
The feed box mechanisms are lubricated through splashing. The oil is changed according to the
scheme on Fig. 28. The box is filled with oil through the plug at the right side of it.
The apron box is lubricated from a piston pump. It is filled with oil through the plug at its right
side up to the middle of the oil level indicator. The three-position oil distributor, mounted on the pump
at the left side of the apron box, feeds oil to the guideways, lead screw nut, or to the apron box. The oil
is changed according to the scheme on Fig. 28, the waste oil being removed through the plug, and the
new one being filtered.
The friction points of the saddle, tailstock and the arm are lubricated with oil cup according to
the scheme on Fig. 28.
Oils with higher viscosity should be used in tropical climate.
Lubrication products

Point of Denotation ac. to

Bulgaria Russia Shell Mobil EP
lubrication ISO 3498
1,15,16 А68 ММО 50 I-50А VITREA 68 VACTRA ENERGOL
CS68
17,18 HEAVY
MEDIUM
4
5 CB 32 MX-M 32 IGP-18 TELLUS 32 DTE 24 ENERGOL
HLP32
7 CB 32 MX-M 32 IGP-18 TELLUS 32 DTE 24 ENERGOL
HLP32
8 Lubrication to be done from point 10
9 Lubrication to be done from point 10
10 GB 100 MX-M 100 IGP-72 TELLUS DTE 28 ENERGOL
100 HLP 100
12 Lubrication to be done from point 10
Universal lathes C404T. Service manual. Page 67
Universal lathes C404T. Service manual. Page 68

Fig. 28

1.11 LABOUR SAFETY PRECAUTIONS

1.11.1 PROTECTIVE ( SAFETY ) DEVICES

1.11.1.1. ON THE MECHANICAL SECTION

- chuck guard - dividing device

- front screen (safety screen for the toolpost) - dividing device
- lateral cover of the quadrant - dividing device
- lateral cover of the main motor driving pulley - dividing device
- rear guard - dividing device
- protected lead-screw and shaft

1.11.1.2. ON THE ELECTRICAL SECTION

- protection by using low operating voltage

- zero protection
- protection against short cuts
- protection against automatic repeatable starting on hen power supply is restored
- protection against direct touch
- protection against overload
- protective breaking of the operating circuit
- zero protected secondary coils of the transformer
- electrical interlock on the quadrant cover and electric cabinet

1.11.2 SAFETY DEVICES ACTION

Described in details in item 1.6

1.11.3 REQUIREMENTS ON THE SAFE WORK WITH THE MACHINE

- use the machine only in conformity with its purpose

- operating the machine in a mode not in conformity with the tools and materials is undesirable
- using tightening devices and appliances not specified in the manual may lead to undesirable
consequences
- do not use materials harmful to health when working
- no self-willed changes must be made in the service manual
- people not instructed on common safety precautions and not acquainted with the present
service manual are not allowed to operate the machine
- wear appropriate shoes
- working clothes must have sleeves, covering well the wrists of hands, properly chosen in size.
Wearing cami-knicks is recommended. Do not wear an overall.
- wearing a cap which must cover well hair is obligatory
- people dealing with installing, service and maintenance of the machine must confirm in
writing that they have understood the present service manual
Universal lathes C404T. Service manual. Page 69

- installing, actuating and service must be done only by qualified staff

- the general lighting level must not be below 200 luxes
- do not operate a machine which is out of order
- do not operate machines which produces noise exceeding admissible rates

SPECIAL REQUIREMENTS AND ADDITIONAL RISKS

- do not operate the machine when its safety devices are open
- do not open covers when the machine operates
- do not carry out any assembly or servicing activities when the machine is power supplied
- do not touch directly, or by any other objects rotating parts of the machine
- wait till the full stop of rotating spindle before operating tightening devices
- do not pollute the work area of the machine
- avoid operating when a continuos ( non-breakable ) chip appears
- check if there are any auxiliary tools in the work area before begin to work
- be careful when working with steadies - there is danger of crush
- be careful when the tailstock moves - there is danger of grazing
- protect yourself from pressing and crush between the apron and gear box; between the apron
and tailstock; between the travelling steady and chuck guard
- do not clear chips by hand; use suitable hook or broom
- work only if the workpiece is well tightened
- do not exceed the highest admissible speed of the tightening devices
Universal lathes C404T. Service manual. Page 70

ENCLOSURES

1.12. EQUIPMENT

Lathe type С404Т.................../.....................mm

Serial number.............................../ year of production 20........

The attachments and spare parts available with your machine are marked with “X”.

Nr. Name of the part Pcs Remark

Standard equipment
1 Main motor 1
O
................................V..........................Hz
.................................rpm
2 Electric installation set with el. switchboard and 1
O control panel
3 V-shaped belts:
O
- А 13 х 8 х 1850 - for С404Т 4
- А 13 х 8 х 1950 - for С404ТМ (ТН) 4
4 Set of change gears :
4a. Change toothed pulleys :metric execution z=24, 64, 33, 7 In the box: 33, 56, 51, 34,
O 56, 51, 34, 46, 39 46, 39
(plus z=27 and z=57 for 19 TPI) (2) (27, 57)
O
4b. Change gears: inch execution: z=42, 80/54, 120, 88, 69, 7 In the box: 88, 69, 33, 69
O 33, 69
(plus z=56 and z=64 for C404TM and TH) (2) (64)
O (plus z=115 for 11.5 TPI (3) (115, 114, 108)
O z=114 for 19 TPI
z=108 for 27 TPI)

5 Levelling bolts 8 (12) in the small case

O
6 Levelling pads 8 (12) in the small case
O
7 Foundation bolts 8 (12) in the small case
O
8 Dead centre МК4 1 in the small case
O
9 Reducing sleeve МT6 / МT4 1 in the small case
O
10 Back plate for universal chuck Ф200 - set 1 in the small case
O
11 Four-position universal toolpost 1
O
12 ”S”-type spanner 1 in the small case
O
13 Double-side spanners: 4 in the small case
O
10 х 12, 14 х 17, 19 х 22, 24 х 27
14 Hexagon wrenches 5, 6 , 8, 10, 12 5 in the small case
O
Universal lathes C404T. Service manual. Page 71

Nr. Name of the part Pcs Remark

15 Screwdriver B 225 х 5 1 in the small case
O
16 Service Manual 1 in the electric cabinet
O
Optional equipment
1 Quick-change universal toolpost 1
O
type В
2 Prismatic toolholder delivered against
O special order
3 Bar toolholder 1 in the small case
O
4 Boring bar toolholder 1 in the small case
O
5 ”Star”-type spanner 1 in the small case
O
6 Coolant equipment - set 1
O
7 Rear safety screen 1
O
8 Front safety screen 1
O
9 Safety shield for chuck Ф200 1
O
10 Safety shield for chuck Ф250 1
O
11 Safety shield for chuck Ф400 1
O
12 Back plate for universal chuck Ф250 1
O
13 Travelling steady 1
O
14 Roller quill for travelling steady 2 in the small case
O
15 Fixed steady Ф140 1
O
16 Fixed steady Ф200 1
O
17 Roller quill for fixed steady 3 in the small case
O
18 Drive plate 1 in the small case
O
19 Three-jaw universal chuck Ф200 1
O
20 Three-jaw universal chuck Ф250 1
O
21 Key for three-jaw universal chuck 1 in the small case
O
22 Independent four-jaw chuck Ф315 1 in the small case
O
23 Independent four-jaw chuck Ф400 1 in the small case
O
24 Live centre МК4 1 in the small case
O
25 Three-jaw drill chuck Ф20 1 in the small case
O
Universal lathes C404T. Service manual. Page 72

Nr. Name of the part Pcs Remark

26 Drill chuck arbor MT4 1 in the small case
O
27 Key for three-jaw drill chuck 1 in the small case
O
28 Set of turning dogs Ф20, Ф30, Ф40, Ф50, Ф60 5 in the small case
O
29 Local lighting 1
O
30 Jawless face plate 1 in the small case
O
31 Taper turning attachment 1
O
32 Six-position stop limiter 1
O
33 Rapid travers device for lathes DBC 750 and 1000 1
O mm
34 Thread dial indicator 1
O
35 Foot brake 1
O
36 Closed screw and shaft 1
O
37 Longitudinal stop 1
O
38 Packing - wooden case 1
O
Fast-wearing spare parts
1 Safety pin for lead screw 1 in the small case
O