WABECO D2000 User manual
Operating Instructions
Lathes
with cylindrical guideways
D2000 D2400 D3000
2
Please read before putting into operation for the rst time!
Every person that operates the machine, maintains or repairs it, must have read the operating
instructions, and in particular, the safety notes prior to putting the machine into operation.
Please store these documents for subsequent use.
Original version in German/translation in English
Status at 06/2018
Dear Customer!
With the purchase of the WABECO machine you have decided in favour of a quality tool. This
machine has been manufactured with the greatest of care and subject to precise quality controls.
These operating instructions are designed to help you to use your new machine safely and correctly.
For this reason, we ask you to read the appropriate notes through attentively and to take care to
observe them.
After unpacking the tool, check whether any transportation damages have occurred. Complaints,
whatever their nature, should be communicated immediately. Subsequent claims cannot be
recognised.
For all queries and replacement part orders, please always specify the machine number (see type
plate).
Reprinting and reproductions of any kind, even extracts, require the written permission of
WABECO
The transportation and protective packaging is made of the following materials:
■ Corrugatedcard
■ PolystyrenewithoutFreon
■ Polyethylenefoil
■ Timberassingle-usepallet(untreated)
■ Europallet(multipleusepackaging)
If you no longer need the items, or you do not want to reuse them, dispose of these items at the
ofciallyrecognisedrecyclingpoints.
The machine is manufactured in such a way that 98% of the used materials that can be recycled,
for example, steel, cast iron, aluminum and only 2% are chemical materials, e.g. cable sleeves of
electricalcables,PCBs.
Ifyouhaveanydifcultiesindisposingofthesepartsproperly,wewouldbehappytohelp:withprior
agreement we will take back the machine in full and dispose of it. You must, however, cover the costs
of sending it to us.
Disposing of the machine
wabeco-rs.de
WalterBlombachGmbH
42899 Remscheid
AmBlaffertsberg13
Germany
Phone+492191597-0
Fax +492191597-42
E-Mail[email protected]
3
Index
Declaration of conformity for D2000 6
Declaration of conformity for D2400 7
Declaration of conformity for D3000 8
1. Important safety notes 9
1.1 Intended use 9
1.2 Improper and incorrect use 9
1.3 Modicationstothemachine 9
1.4 Safety regulations for proper use 9
1.5 Safetyfeatures 12
1.6 Explanations of the symbols 12
2. Delivery and set up 13
2.1 Transporting the machine 14
3. Putting into operation 15
4. Specications regarding the machine 15
4.1 Identicationofthemodel 15
4.2 D2000 15
4.2.1 Declarationofnoiselevels 15
4.2.2 Technical data 16
4.2.3 Dimensions 17
4.3 D2400 17
4.3.1 Declarationofnoiselevels 17
4.3.2 Technicaldata 18
4.3.3 Dimensions 19
4.4 D3000 19
4.4.1 Declaration of noise levels 19
4.4.2 Technical data 20
4.4.3 Dimensions 21
4.5 Revolutionselection 21
4.6 Diagram for reading off the revolutions 22
4.7 Revolutionchanger 22
4.8 Electricalequipment 23
5. Achieving optimum results 24
and avoiding incorrect usage
6. Thread cutting and automatic feed 26
6.1 Thread cutting 26
6.2 Useofchangegears 27
6.3 Left-handthread(optional) 31
7. Maintenance 32
8. Lubrication of the machine 32
9. Re-adjusting the main spindle 33
4
Index
10. Re-adjusting the tool slide 34
11. Tailstock 35
12. 3- and 4-jaw lathe chuck 36
13. Operational faults and the elimination of such 37
14. Control elements 40
14.1 D2000 and D2400 lathes 40
14.2 D3000lathe 41
15. Drawings and legends 42
15.1 Headstock 42
15.2 FoundationwithmotorandcovercapforD2000/D2400 44
15.3 FoundationwithmotorandcovercapforD3000 46
15.4 ChangegearquadrantforD2000/D2400/D3000 48
15.5 TransmissionandleadscrewdriveforD2000/D2400/D3000 50
15.6 LeadscrewdriveforD3000 54
15.7 Toolslide–longitudinalslide 56
15.8 Toolslide–crossslide 58
15.9 Tailstock 60
15.10 RearbearingwithguiderodsforD2000/D2400 62
15.11 RearbearingwithguiderodsforD3000 64
16. Circuit diagram 66
16.1 For D2000/D2400 66
16.2 ForD3000 67
16.3 Keyforcircuitdiagram 68
17. Chip tray with splash guard (optional) 69
17.1 Settingupthechiptraywithsplashguard 69
17.2 Mountingthechiptraywithsplashguardonthe 70
machine base cabinet (optional)
17.3 Drawingandlegend 71
18. Coolant unit (optional) 72
18.1 Settingupthecoolantunit 72
18.2 Mountingofthecoolantunittothe 73
machine base cabinet (optional)
18.3 Safetyregulationsforthehandlingofcoolinglubricant 74
18.4 Fillingthecoolantunit 75
18.5 Operatingthecoolantunit 75
18.6 Positioningthesegmentedcoolanthose 76
18.7 Controllingtheowofcoolantusingthecoolantshut-offvalve 76
18.8 Drawingandlegend 77
5
Index
19. Fixed stay 79
19.1 Operatingthexedstay 79
19.2 Drawing and legend 80
20. Live stay 81
20.1 Operating the live stay 81
20.2 Drawing and legend 82
21. Clamping angle with milling attachment (optional) 83
21.1 Mountingtheclampinganglewithmillingattachmenttothelathe 83
21.2 Controlelements 85
21.3 Feedmotionofthemillingattachment 85
21.4 Adjustment of the dovetail guide 86
21.5 Alignmentofthemillingattachment 86
21.6 Lubricationoftheclampinganglewithmillingattachment 86
21.7 Drawingandlegend 87
22. Collet chuck (optional) 88
22.1 Mountingthecollectchuck 88
22.2 Drawing and legend 88
22.3 Installationandremovalofcollets 89
6
Declaration of conformity
We hereby declare, in the name of the manufacturer
Walter Blombach GmbH
Werkzeug- und Maschinenfabrik
with headquarters in Remscheid and Neuerburg
D-42871Remscheid Postfach120161 Telefon:(02191)597-0 Fax:(02191)597-42
D-54673Neuerburg WABECOStr.1-10 Telefon:(06564)9697-0 Fax:(06564)9697-25
that the following named
Universal lathe
Type:
D2000
in the serial version, meets the following relevant regulations
- Machinery Directive 2006/42 EG
- EMC Directive 2014/30/EU
- Low Voltage Directive 2014/35/EU
Inordertofull/implementtherequirementsofthedirectivesnamedabove,thealready
published and applicable standards were drawn upon:
EN ISO 12100:2010
DIN EN 60204-1:2007
DIN EN ISO 23125:2015
Proxyforthecompilationofthetechnicaldocumentationistheoperationalheadofthe
abovenamedmanufacturer,MrChristophSchneider.
D-54673Neuerburg2018
________________________________
Placeanddateofissue
________________________________
Operational head Christoph Schneider
7
Declaration of conformity
We hereby declare, in the name of the manufacturer
Walter Blombach GmbH
Werkzeug- und Maschinenfabrik
with headquarters in Remscheid and Neuerburg
D-42871Remscheid Postfach120161 Telefon:(02191)597-0 Fax:(02191)597-42
D-54673Neuerburg WABECOStr.1-10 Telefon:(06564)9697-0 Fax:(06564)9697-25
that the following named
Universal lathe
Type:
D2400
in the serial version, meets the following relevant regulations
- Machinery Directive 2006/42 EG
- EMC Directive 2014/30/EU
- Low Voltage Directive 2014/35/EU
Inordertofull/implementtherequirementsofthedirectivesnamedabove,thealready
published and applicable standards were drawn upon:
EN ISO 12100:2010
DIN EN 60204-1:2007
DIN EN ISO 23125:2015
Proxyforthecompilationofthetechnicaldocumentationistheoperationalheadofthe
abovenamedmanufacturer,MrChristophSchneider.
D-54673Neuerburg2018
________________________________
Placeanddateofissue
________________________________
Operational head Christoph Schneider
8
Declaration of conformity
We hereby declare, in the name of the manufacturer
Walter Blombach GmbH
Werkzeug- und Maschinenfabrik
with headquarters in Remscheid and Neuerburg
D-42871Remscheid Postfach120161 Telefon:(02191)597-0 Fax:(02191)597-42
D-54673Neuerburg WABECOStr.1-10 Telefon:(06564)9697-0 Fax:(06564)9697-25
that the following named
Universal lathe
Type:
D3000
in the serial version, meets the following relevant regulations
- Machinery Directive 2006/42 EG
- EMC Directive 2014/30/EU
- EU Low Voltage Directive 2014/35/EU
Inordertofull/implementtherequirementsofthedirectivesnamedabove,thealready
published and applicable standards were drawn upon:
EN ISO 12100:2010
DIN EN 60204-1:2007
DIN EN ISO 23125:2015
Proxyforthecompilationofthetechnicaldocumentationistheoperationalheadofthe
abovenamedmanufacturer,MrChristophSchneider.
D-54673Neuerburg2018
________________________________
Placeanddateofissue
________________________________
Operational head Christoph Schneider
9
1. Important safety notes
1.1 Intended use
The lathes described in these operating instructions are designed for the processing of metal, plastic
and timber only.
To ensure safe operation of the lathes, the regulations set out in the chapter: „Safety regulations“ must
be observed.
The lathes described in these operating instructions have been developed and manufactured for the
purpose named above. Walter Blombach GmbH accepts no responsibility for property damage and
personal injury caused as a result of not intended and incorrect use of the lathes.
1.2 Improper and incorrect use
1.3 Modications to the machine
Forreasonsofsafety,itisforbiddenfortheusertomakemodicationsofanytypetothelathe.
WalterBlombachGmbHacceptsnoresponsibilityforpropertydamageandpersonalinjurycausedas
aresultofanymodicationstothelathebytheuserthathavenotexpresslybeenauthorisedbythe
company.
1.4 Safety regulations for proper use
The machine may represent a source of danger if it is not used correctly. For this reason, it is important
that the following safety regulations are read attentively and observed carefully.
Every person that operates the machine, maintains or repairs it, must have read the operating
instructions, and in particular, the safety notes prior to putting the machine into operation.
In order to full these requirements, these operating instructions must accompany the machine
throughout its entire lifetime and be available for research.
In the event that the machine changes owners, the operating instructions must thus be passed on to
the new owner along with the machine.
10
1. Important safety notes
1.4 Safety regulations for proper use
1. Only specially trained persons may operate the machine. The guarantee and warranty are
voided if damages are caused by improper operation.
2. We remind you that no liability will be accepted for damages caused by not observing these
operating instructions.
3. The operator of the machine is to ensure that at least one copy of the operating instructions is
stored in the immediate vicinity of the machine and available to the people who work with the
machine.
4. Theoperatoristoensurethatthesafetyanddangernoticationsonthemachineareobserved
and that the signs are kept in a legible state.
5. Do not work without goggles.
6. Wearclosettingclothingand,ifyouhavelonghair,wearahairnet.Donotwearloosettingor
loose items (ties, shirt sleeves, jewellery etc.).
7. Gloves may not be worn.
8. Intheeventofanemissionnoiselevelasof80dB(A)attheworkplace,eardefendersmustbe
worn.
9. The machine may not operate without supervision.
10. Secureyourmachineinsuchawaythatitcannotbeswitchedonbychildren.Personswhohave
not been trained may not operate the machine.
11. Beforeusingthemachine,makesureitisingoodworkingcondition.Payspecialattentiontoany
damagetothegroundedplugortheelectricalconnections.Neveroperatethemachinewitha
defective, crushed or exposed cable.
12. Plugthegroundedplugintoasuitablesocketforthemachine.Thecableforthemachinemay
onlybeconnectedtoasafetysocketoraconnectionbox.Havethesafetysocketorconnection
box checked by an electrical specialist before hand.
13. The safety socket or connection box must be close enough to the machine that the power cable
is not under strain.
14. When carrying out maintenance and cleaning work, the machine must be switched off and the
grounded plug pulled out.
15. Set-upworkisonlytobecarriedoutwiththemachineswitchedoff.
16. Do not reach into the operating machine.
17. Always switch the machine off when you are not using it.
18. Remain with the machine until it has come to a standstill.
11
1. Important safety notes
1.4 Safety regulations for proper use
19. Onlyhaverepairscarriedoutbyaqualiedspecialist!Repairworkmayonlybecarriedoutby
personswhoarequaliedfortherelevantrepairsandwhoarefamiliarwiththeappropriatehealth
and safety requirements.
20. Protectthemachinefromdamp.
21. Constantly check the machine for damages. Replace damaged parts only with original parts and
have these replaced by a specialist. The guarantee and warranty is voided if accessories and
replacement parts are use that are not designed for the machine.
22. Toavoidinsufcientlighting,werecommendsettingupalightsourcethatprovidesavalueofat
least500Luxatthetool‘scuttingedge.
23. Do not remove the generated shavings with your hand. Use the appropriate tools (hand-
held sweeper, hook, brush).
24. Tools and workpieces may never be changed when the machine is running.
25. Do not brake workpieces and bush using your hand or another object.
26. Neverleavethechuckkeytted(evenwhennotinoperation).
27. Payattentiontothespreadofthelathechuck.
28. Themaximumrevolutionrangespeciedonthelathechuckmaynotbeexceeded.
29. The machine only operates when the chuck protection hood is folded over the lathe chuck. For
safety reasons, it is not possible to switch the machine on when the chuck protection hood is up.
30. The generated shavings must be caught by the user with the help of a shaving protection device.
31. Always keep the gear cover hood closed.
32. The gear cover hood may only be opened by a trained person with a special key and when the
grounded plug has been pulled out of the socket.
33. Turningsteelsmustbermlytensioned,atthecorrectheightandasshortaspossible.
34. Do not measure at the rotating workpiece (risk of accident, measuring tools will be damaged).
35. Whenworkingbetweenthetips,checkthelockingleverofthetailstockforrmseating.
36. Despite the existing safety clutch, you should avoid reaching into the rotating hand wheel when
the automatic feed is switched on.
37. When working with the automatic feed, always pay attention to ensure that the tool slide does not
come up against the lathe chuck or the tailstock.
38. When wood turning use a lathe center point instead of the lathe chuck to carry the workpiece.
12
1.5 Safety features
1. Important safety notes
In order to enable you to work safely with our machines, we have incorporated the following safety
mechanisms. These meet the relevant European safety requirements.
■Chuck protection hood
The main spindle of the machine operates only with the chuck protection hood closed. For safety
reasons, if the chuck protection hood is open, the machine cannot be switched on.
■Gear cover hood
Always keep the gear cover hood closed. The gear cover hood may only be opened by a trained
person with a special key and when the grounded plug has been pulled out of the socket.
■ON/OFF switch with under-voltage trigger
TheON/OFFswitchisttedwithanunder-voltagetrigger,thus,intheeventofapowerfailure,the
machine does not switch itself back on automatically. This prevents risks caused by the unexpected
motion of the spindle.
■Emergency off switch
The emergency off switch acts to quickly stop the machine.
■Overload protection
Themachineisttedwithanoverloadprotectionfeature.Thisoverloadprotectionfeatureswitches
the main drive motor off automatically when the machine is overloaded. The machine can only then
be switched on after a waiting period.
1.6 Explanations of the symbols
With a measured noise level of 80 dB (A) at the work-
place the operator should wear Ear Protection.
Caution:
Always pull the power plug prior to any maintenance
work!
Read the operating instructions prior to initial operation or
maintenancework!
Caution:
Dangerouselectricvoltage!
13
2. Delivery and set up
The machine is packed with care at the factory.
The following should be checked after delivery:
1. Whether the packaging shows damages to be reported or
2. Whether the machine shows transportation damages to be reported If this is the case, we ask you
to communicate this information immediately. Subsequent claims cannot be recognised.
Themachinemustbesetuponasuitable,evenandrmsurface.
Suitable surfaces are, for example:
■A machine base cabinet (available optionally).
■A separate workbench with a level surface (spirit level) that is strong enough to carry the weight of
the lathe without bending.
■A steel plate with a level surface (spirit level).
The machine must be screwed securely to the surface it is set up on. There are holes in the base of
the machine that are designed for this purpose. Good working results and low-vibration operation
can only be ensured when the prerequisites for xture as set out above are maintained.
The place of set up should be selected in such a way that
■ thereissufcientlighting.
■the electrical power supply with safety socket and earth are installed close enough to the machine
that the power cable is not subject to any strain.
■the power cable should also be dimensioned in such a way that a multiple socket can be used, for
example, to power a coolant unit.
14
Werecommendtwopeopletoliftthemachine,usingthepositionsshown(1).Todothis,asufciently
dimensioned, at least Ø 20 mm steel rod is pushed through the main spindle. The machine should be
carried and balanced by one person at the steel rod and by the other person, at the shown position on
the opposite underside of the bed.
Whenlifting,payattentiontoanergonomicstanceandsufcientsafety!
In the delivered state, the machine feet have two transport straps attached. These secure the
machine to the transportation pallet. They must be removed before setting the machine up.
2.1 Transporting the machine
2. Delivery and set up
0
VORW
NOT
AUS
RUECKW
1 2
1
15
3. Putting into operation
■Use a dry cloth to remove the corrosion protection that was applied to all exposed parts for transport.
■In the event of marine impregnation of exposed parts, it is recommended you spray them with oil,
allow it to work, and then remove the impregnation with a dry cloth.
■Once set up properly (see the section on delivery and set up) connect the grounded plug directly to
asafetysocketandthe230V50/60Hz(optional110V60Hz)mainspowersupply.
■ Provisionofsufcientcoolantfortheoperationofacoolantunit(optional).
■Release the axis clamps and check the individual feed spindles for easy operation.
■ Check all electronic control elements, for example, ON/OFF switch, emergency off switch,
potentiometer, bush protection hood, etc. for functionality.
4. Specications regarding the machine
4.1 Identication of the model
The precise model designation of your machine can be found on the type plate attached to the
machine.
4.2.1 Declaration of noise levels
Declaration of noise levels in accordance with DIN EN ISO 3744
Emission values in idle
Emission sound pressure level at the workplace
at50% =60.8dB(A
at 100 % =72.0dB(A)
Sound power level
at50% =70.4dB(A)
at 100 % =81.9dB(A)
Atanemissionsoundpressurelevelfrom80dB(A)andaboveattheworkplace
ear protection is required.
4.2 D2000
16
Working range
Center distance 350mm
Center height 110 mm
Turning Ø above cross slide 126 mm
Turning Ø above the guideways 220 mm
Main drive motor
Nominalvoltage 230V
Nominalfrequency 50/60Hz
Nominalperformanceofthespindlemotor 1.4 kW
Spindlerevolutions,innite 30-2300rpm
Machine accuracy
True running accuracy of the spindle nose 0.005mm
Cylindrical turning to 100 mm cantilevered 0.01 mm
Cylindricalturningwithanishingcutto300mm
between the centers 0.015mm
Headstock
Mainspindlebore Ø 20 mm
Taper in main spindle MT3
Mainspindlenose accordingtoDIN6350
Tool slide
Travel of cross slide 110 mm
Travel of longitudinal slide 58mm
Longitudinalslidecanbeswiveledthrough 360°
Max.heightofturningtools 20 mm
Tailstock with quick adjustment
Lateraladjustabilityoftailstockupperpart ± 10 mm
Tailstock sleeve withinnermorsetaperMT2
Travel of tailstock sleeve 65mm
Scale 1 mm
Thread cutting (prepared)
With lead screw drive and change gear quadrant right-handthread
Automatic longitudinal feed rate 0.085rpm
Optional
Change gear set for thread cutting
metric0.25-6.0mm-inch10-36TPI
automatic longitudinal feeds 0.16 rpm
4. Specications regarding the machine
4.2.2 Technical data
4.2 D2000
17
4. Specications regarding the machine
4.2.3 Dimensions
4.3.1 Declaration of noise levels
Declaration of noise levels in accordance with DIN EN ISO 3744
Emission values in idle
Emission sound pressure level at the workplace
at50% =60.8dB(A
at 100 % =72.0dB(A)
Sound power level
at50% =70.4dB(A)
at 100 % =81.9dB(A)
Atanemissionsoundpressurelevelfrom80dB(A)andaboveattheworkplace
ear protection is required.
4.2 D2000
4.3 D2400
18
Working range
Center distance 500mm
Center height 110 mm
Turning Ø above cross slide 126 mm
Turning Ø above the guideways 220 mm
Main drive motor
Nominalvoltage 230V
Nominalfrequency 50/60Hz
Nominalperformanceofthespindlemotor 1.4 kW
Spindlerevolutions,innite 30-2300rpm
Machine accuracy
True running accuracy of the spindle nose 0.005mm
Cylindrical turning to 100 mm cantilevered 0.01 mm
Cylindricalturningwithanishingcutto300mm
between the centers 0.015mm
Headstock
Mainspindlebore Ø 20 mm
Taper in main spindle MT3
Mainspindlenose accordingtoDIN6350
Tool slide
Travel of cross slide 110 mm
Travel of longitudinal slide 58mm
Longitudinalslidecanbeswiveledthrough 360°
Max.heightofturningtools 20 mm
Tailstock with quick adjustment
Lateraladjustabilityoftailstockupperpart ± 10 mm
Tailstock sleeve withinnermorsetaperMT2
Travel of tailstock sleeve 65mm
Scale 1 mm
Thread cutting (prepared)
With lead screw drive and change gear quadrant right-handthread
Automatic longitudinal feed rate 0.085rpm
Optional
Change gear set for thread cutting
metric0.25–6.0mm-inch10-36TPI
automatic longitudinal feeds 0.16 rpm
4. Specications regarding the machine
4.3.2 Technical data
4.3 D2400
19
4. Specications regarding the machine
4.3.3 Dimensions
4.4.1 Declaration of noise levels
Declaration of noise levels in accordance with DIN EN ISO 3744
Emission values in idle
Emission sound pressure level at the workplace
at50% =60.8dB(A
at 100 % =72.0dB(A)
Sound power level
at50% =70.4dB(A)
at 100 % =81.9dB(A)
Atanemissionsoundpressurelevelfrom80dB(A)andaboveattheworkplace
ear protection is required.
4.3 D2400
4.4 D3000
20
Working range
Center distance 500mm
Center height 110 mm
Turning Ø above cross slide 126 mm
Turning Ø above the guideways 220 mm
Main drive motor
Nominalvoltage 230V
Nominalfrequency 50/60Hz
Nominalperformanceofthespindlemotor 1.4 kW
Spindlerevolutions,innite 30-2300rpm
Machine accuracy
True running accuracy of the spindle nose 0.005mm
Cylindrical turning to 100 mm cantilevered 0.01 mm
Cylindricalturningwithanishingcutto300mm
between the centers 0.015mm
Headstock
Mainspindlebore Ø 20 mm
Taper in main spindle MT3
Mainspindlenose accordingtoDIN6350
Tool slide
Travel of cross slide 110 mm
Travel of longitudinal slide 58mm
Longitudinalslidecanbeswiveledthrough 360°
Max.heightofturningtools 20 mm
Tailstock with quick adjustment
Lateraladjustabilityoftailstockupperpart ± 10 mm
Tailstock sleeve withinnermorsetaperMT2
Travel of tailstock sleeve 65mm
Scale 1 mm
Thread cutting
With lead screw drive and change gear quadrant right-handthread
Automatic longitudinal feed rate 0–250mm/min
Change gear set for thread cutting metric0.25-6.0mm-inch10-36TPI
4. Specications regarding the machine
4.4.2 Technical data
4.4 D3000
Other manuals for D2000
1
This manual suits for next models
2
Table of contents
Other WABECO Lathe manuals
