WABECO D2000 User manual

Operating Instructions
Lathes
with cylindrical guideways
D2000 D2400 D3000

2
Please read before putting into operation for the first 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 10/2014
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
Disposing of the machine
The transportation and protective packaging is made of the following materials:
■Corrugated card
■Polystyrene without Freon
■Polyethylene foil
■Timber as single-use pallet (untreated)
■Euro pallet (multiple use packaging)
If you no longer need the items, or you do not want to reuse them, dispose of these items at the
officially recognised recycling points.
The machine is manufactured in such a way that 98% of the used materials that can be recycled, for
example, steel, cast iron, aluminium and only 2% are chemical materials, e.g. cable sleeves of
electrical cables, PCBs.
If you have any difficulties in disposing of these parts properly, we would be happy to help: with prior
agreement we will take back the machine in full and dispose of it. You must, however, cover the costs
of sending it to us.
wabeco-rs.de
Walter Blombach GmbH
42899 Remscheid
Am Blaffertsberg 13
Germany
Tel. [phone]
Fax [phone]
E-Mail [e-mail]

3
Contents
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 Modifications to the machine 9
1.4 Safety regulations for proper use 9
1.5 Safety features 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. Specifications regarding the machine 15
4.1 Identification of the model 15
4.2 Noise emission declaration for D2000 15
4.2.1 Technical data D2000 16
4.2.2 Dimensions of D2000 17
4.3 Noise emission declaration for D2400 17
4.3.1 Technical data D2400 18
4.3.2 Dimensions of D2400 19
4.4 Noise emission declaration for D3000 19
4.4.1 Technical data D3000 20
4.4.2 Dimensions of D3000 21
4.5 Revolution selection 21
4.6 Diagram for reading off the revolutions 22
4.7 Revolution changer 22
4.8 Electrical equipment 23
5. Achieving optimum results 24
and avoiding incorrect usage
6. Thread cutting and automatic feed 26
6.1 Thread cutting 26
6.2 Use of change gears 27
6.3 Lefthand thread 31
7. Maintenance 32
8. Lubrication of the machine 32
9. Readjusting the main spindle 33
10. Readjusting the tool skid 34
11. Tailstock 35

4
Contents
12. 3 and 4 jaw lathe chuck 36
13. Operational faults and the elimination of such 37
14. Operating elements 40
14.1 D2000 und D2400 lathes 40
14.2 D3000 lathes 41
15. Drawings and legends 42
15.1 Headstock 42
15.2 Foundation with motor and cover cap for D2000/D2400 44
15.3 Foundation with motor and cover cap for D3000 46
15.4 Change gear quadrant for D2000/D2400/D3000 48
15.5 Transmission und lead screw drive for D2000/D2400/D3000 50
15.6 Lead screw engine for D3000 54
15.7 Tool skid – Longitudinal skid 56
15.8 Tool skid – Transverse skid 58
15.9 Tailstock 60
15.10 Rear bearing with guide rods for D2000/D2400 62
15.11 Rear bearing with guide rods for D3000 64
16. Circuit diagram 66
16.1 for D2000/D2400 66
16.2 for D3000 67
16.2 Key for circuit diagram 68
17. Shavings tank with spray protection wall (optional) 69
17.1 Setting up the shavings tank with spray protection wall 69
17.2 Mounting the shavings tank with spray protection wall on the 70
tool machine cabinet (optional)
17.3 Drawing and legend 71
18. Coolant system (optional) 72
18.1 Setting up the coolant system 72
18.2 Mounting of the coolant system to the 73
tool machine cabinet (optional)
18.3 Safety regulations for the handling of cooling lubricant 74
18.4 Filling the coolant system 75
18.5 Operating the coolant system 75
18.6 Positioning the segmented coolant hose 76
18.7 Controlling the flow of coolant using the coolant shut-off valve 76
18.8 Drawing and legend 77
19. Fixed bezel 79
19.1 Operating the fixed bezel 79
19.2 Drawing and legend 80
20. Moving bezel 81
20.1 Operating the moving bezel 81
20.2 Drawing and legend 82

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Contents
21. Tensioning bracket with milling machine table (optional) 83
21.1 Mounting the tensioning bracket with milling machine table to the lathe 83
21.2 Operating elements 85
21.3 Feed motion of the milling machine table 85
21.4 Adjustment of the dovetail guide 86
21.5 Alignment of the milling machine table 86
21.6 Lubrication of the tensioning bracket with milling machine table 86
21.7 Drawing and legend 87
22. Collet chuck (optional) 88
22.1 Mounting the collect chuck 88
22.2 Drawing and legend 88
22.3 Installation and removal of collets 89

6
Declaration of conformity
We hereby declare, in the name of the manufacturer
Walter Blombach GmbH
Werkzeug- und Maschinenfabrik
mit Sitz in Remscheid und Neuerburg
D-42871 Remscheid Postfach 12 01 61 Telefon: [phone] Fax: [phone]
D-54673 Neuerburg WABECO Str. 1-10 Telefon: [phone] Fax: [phone]
that the following named
Universal lathe
Type:
D2000
in the serial version, meets the following relevant regulations
- EU Machine Directive 2006/42/EC
- EMC Directive 2004/108/EC
- EU Low Voltage Directive 2006/95/EC
In order to fulfil/implement the requirements of the directives named above, the already
published and applicable standards were drawn upon:
EN ISO 12100:2010
DIN EN 60204-1:2006
EN ISO 23125:2010
Proxy for the compilation of the technical documentation is the operational head of the
above named manufacturer, Mr Christoph Schneider.
D-54673 Neuerburg 2014
________________________________
Place and date of issue
Operational head Christoph Schneider

7
Declaration of conformity
We hereby declare, in the name of the manufacturer
Walter Blombach GmbH
Werkzeug- und Maschinenfabrik
mit Sitz in Remscheid und Neuerburg
D-42871 Remscheid Postfach 12 01 61 Telefon: [phone] Fax: [phone]
D-54673 Neuerburg WABECO Str. 1-10 Telefon: [phone] Fax: [phone]
that the following named
Universal lathe
Type:
D2400
in the serial version, meets the following relevant regulations
- EU Machine Directive 2006/42/EC
- EMC Directive 2004/108/EC
- EU Low Voltage Directive 2006/95/EC
In order to fulfil/implement the requirements of the directives named above, the already
published and applicable standards were drawn upon:
EN ISO 12100:2010
DIN EN 60204-1:2006
EN ISO 23125:2010
Proxy for the compilation of the technical documentation is the operational head of the
above named manufacturer, Mr Christoph Schneider.
D-54673 Neuerburg 2014
________________________________
Place and date of issue
Operational head Christoph Schneider

8
Declaration of conformity
We hereby declare, in the name of the manufacturer
Walter Blombach GmbH
Werkzeug- und Maschinenfabrik
mit Sitz in Remscheid und Neuerburg
D-42871 Remscheid Postfach 12 01 61 Telefon: [phone] Fax: [phone]
D-54673 Neuerburg WABECO Str. 1-10 Telefon: [phone] Fax: [phone]
that the following named
Universal lathe
Type:
D3000
in the serial version, meets the following relevant regulations
- EU Machine Directive 2006/42/EC
- EMC Directive 2004/108/EC
- EU Low Voltage Directive 2006/95/EC
In order to fulfil/implement the requirements of the directives named above, the already
published and applicable standards were drawn upon:
EN ISO 12100:2010
DIN EN 60204-1:2006
EN ISO 23125:2010
Proxy for the compilation of the technical documentation is the operational head of the
above named manufacturer, Mr Christoph Schneider.
D-54673 Neuerburg 2014
________________________________
Place and date of issue
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.
1.2 Improper and incorrect use
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.
1.3 Modifications to the machine
For reasons of safety, it is forbidden for the user to make modifications of any type to the lathe.
Walter Blombach GmbH accepts no responsibility for property damage and personal injury caused as
a result of any modifications to the lathe by the user that have not expressly been authorised by the
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 fulfil 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.

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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. The operator is to ensure that the safety and danger notifications on the machine are
observed and that the signs are kept in a legible state.
5. Do not work without goggles.
6. Wear close fitting clothing and, if you have long hair, wear a hair net. Do not wear loose
fitting or loose items (ties, shirt sleeves, jewellery etc.).
7. Gloves may not be worn.
8. In the event of an emission noise level as of 80 dB (A) at the workplace, ear defenders must
be worn.
9. The machine may not operate without supervision.
10. Secure your machine in such a way that it cannot be switched on by children. Persons who
have not been trained may not operate the machine.
11. Before using the machine, make sure it is in good working condition. Pay special attention
to any damage to the grounded plug or the electrical connections. Never operate the
machine with a defective, crushed or exposed cable.
12. Plug the grounded plug into a suitable socket for the machine. The cable for the machine
may only be connected to a safety socket or a connection box. Have the safety socket or
connection 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-up work is only to be carried out with the machine switched off.
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.

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1. Important safety notes
1.4 Safety regulations for proper use
19. Only have repairs carried out by a qualified specialist! Repair work may only be carried out
by persons who are qualified for the relevant repairs and who are familiar with the
appropriate health and safety requirements.
20. Protect the machine from damp.
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. To avoid insufficient lighting, we recommend setting up a light source that provides a value
of at least 500 Lux at the tool's cutting edge.
23. Do not remove the generated shavings with your hand. Use the appropriate tools (hand-
held sweeper, hook, brush).
24. Tools and work pieces may never be changed when the machine is running.
25. Do not brake work pieces and bush using your hand or another object.
26. Never leave the chuck key fitted (even when not in operation).
27. Pay attention to the spread of the lathe chuck.
28. The maximum revolution range specified on the lathe chuck may not be exceeded.
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. Turning steels must be firmly tensioned, at the correct height and as short as possible.
34. Do not measure at the rotating work piece (risk of accident, measuring tools will be
damaged).
35. When working between the tips, check the locking lever of the tailstock for firm seating.
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 skid
does not come up against the lathe chuck or the tailstock.
38. When wood turning use a lathe centre point instead of the lathe chuck to carry the work
piece.

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1. Important safety notes
1.5 Safety features
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
The ON/OFF switch is fitted with an under-voltage trigger, thus, in the event of a power failure, 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
The machine is fitted with an overload protection feature. This overload protection feature switches
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 an emission noise level as of 80 dB (A) at the
workplace
ear defenders must be worn
Caution:
Always pull the power plug prior to any maintenance work!
Read the operating instructions prior to initial operation or
maintenance work!
Caution:
Dangerous electric voltage!

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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.
The machine must be set up on a suitable, even and firm surface.
Suitable surfaces are, for example:
■A tool 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 fixture as set out above are maintained.
The place of set up should be selected in such a way that
■There is sufficient lighting
■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 system.

14
2. Delivery and set up
2.1 Transporting the machine
We recommend two people to lift the machine, using the positions shown (1).
To do this, a sufficiently 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..
When lifting, pay attention to an ergonomic stance and sufficient safety!
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.

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
a safety socket and the 230 V 50/60 Hz (optional 110 V 60 Hz) mains power supply.
■Provision of sufficient coolant for the operation of a coolant system (optional).
■Release the axis clamps and check the individual feed spindles for easy operation.
■Check all electronic operating elements, for example, ON/OFF switch, emergency off switch,
potentiometer, bush protection hood, etc. for functionality.
4. Specifications regarding the machine
4.1 Identification of the model
The precise model designation of your machine can be found on the type plate attached to the
machine.
4.2 Noise emission declaration D2000
Noise emission declaration in accordance with DIN EN ISO 3744
Emission values in idle
Emission noise level at the workplace
at 50 % = 60.8 dB (A
at 100 % = 72.0 dB (A)
Sound power level
at 50 % = 70.4 dB (A)
at 100 % = 81.9 dB (A)
With an emission noise level as of 80 dB (A) at the workplace
ear defenders must be worn

16
4. Specifications regarding the machine
4.2.1 Technical data for D2000
Working areas
Distance between centres
350 mm
Centre height
110 mm
Swing diameter via guide
126 mm
Bed width
220 mm
Main drive motor
Nominal voltage
230 V
Nominal frequency
50/60 Hz
Nominal performance of the spindle motor
1.4 kW
Spindle revolutions, infinite
30 - 2300 rpm
Machine accuracy
Concentricity of the spindle lug
0.005 mm
Cylindrical rotation on 100 mm overhung
0.01 mm
Cylindrical rotation with simple turning on 300 mm between
the centres
0.015 mm
Headstock
Main spindle aperture Ø 20 mm
Taper in main spindle MK3
Main spindle lug According to DIN 6350
Tool skid
Adjustability of the transverse skid 110 mm
Adjustability of the longitudinal skid 58 mm
Longitudinal skid can be swivelled by 360°
Max. turning steel height 20 mm
Tailstock with quick adjustment
Lateral adjustability of the tailstock upper ± 10 mm
Tailstock sleeve With inner Morse taper MK2
Sleeve adjustability 65 mm
Scale 1 mm
Thread cutting (geared up)
With lead screw and change gear quadrant Right thread
Automatic longitudinal feed 0.085 rpm
Optional
Change gear set for thread cutting
Metric 0.25 - 6,0 mm - imperial 10 - 36 G/"
Automatic longitudinal feeds 0.16 rpm

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4. Specifications regarding the machine
4.2.2 Dimensions of D2000
4.3 Noise emission declaration D2400
Noise emission declaration in accordance with DIN EN ISO 3744
Emission values in idle
Emission noise level at the workplace
at 50 % = 60.8 dB (A
at 100 % = 72.0 dB (A)
Sound power level
at 50 % = 70.4 dB (A)
at 100 % = 81.9 dB (A)
With an emission noise level as of 80 dB (A) at the workplace
ear defenders must be worn
4x M8 nuts (welded on)

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4. Specifications regarding the machine
4.3.1 Technical data for D2400
Working areas
Distance between centres
500 mm
Centre height
110 mm
Swing diameter via guide
126 mm
Bed width
220 mm
Main drive motor
Nominal voltage
230 V
Nominal frequency
50/60 Hz
Nominal performance of the spindle motor
1.4 kW
Spindle revolutions, infinite
30 - 2300 rpm
Machine accuracy
Concentricity of the spindle lug
0.005 mm
Cylindrical rotation on 100 mm overhung
0.01 mm
Cylindrical rotation with simple turning on 300 mm between
the centres
0.015 mm
Headstock
Main spindle aperture Ø 20 mm
Taper in main spindle MK3
Main spindle lug According to DIN 6350
Tool skid
Adjustability of the transverse skid 110 mm
Adjustability of the longitudinal skid 58 mm
Longitudinal skid can be swivelled by 360°
Max. turning steel height 20 mm
Tailstock with quick adjustment
Lateral adjustability of the tailstock upper ± 10 mm
Tailstock sleeve With inner Morse taper MK2
Sleeve adjustability 65 mm
Scale 1 mm
Thread cutting (geared up)
With lead screw and change gear quadrant Right thread
Automatic longitudinal feed 0.085 rpm
Optional
Change gear set for thread cutting
Metric 0.25 – 6.0 mm - imperial 10 - 36 G/"
Automatic longitudinal feeds 0.16 rpm

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4. Specifications regarding the machine
4.3.2 Dimensions of D2400
4.4 Noise emission declaration D3000
Noise emission declaration in accordance with DIN EN ISO 3744
Emission values in idle
Emission noise level at the workplace
at 50 % = 60.8 dB (A
at 100 % = 72.0 dB (A)
Sound power level
at 50 % = 70.4 dB (A)
at 100 % = 81.9 dB (A)
With an emission noise level as of 80 dB (A) at the workplace
ear defenders must be worn
4x M8 nuts (welded on)

20
4. Specifications regarding the machine
4.4.1 Technical data for D3000
Working areas
Distance between centres
500 mm
Centre height
110 mm
Swing diameter via guide
126 mm
Bed width
220 mm
Main drive motor
Nominal voltage
230 V
Nominal frequency
50/60 Hz
Nominal performance of the spindle motor
1,4 kW
Spindle revolutions, infinite
30 - 2300 rpm
Machine accuracy
Concentricity of the spindle lug
0,005 mm
Cylindrical rotation on 100 mm overhung
0,01 mm
Cylindrical rotation with simple turning on 300 mm between
the centres
0,015 mm
Headstock
Main spindle aperture Ø 20 mm
Taper in main spindle MK3
Main spindle lug According to DIN 6350
Tool skid
Adjustability of the transverse skid 110 mm
Adjustability of the longitudinal skid 58 mm
Longitudinal skid can be swivelled by 360°
Max. turning steel height 20 mm
Tailstock with quick adjustment
Lateral adjustability of the tailstock upper ± 10 mm
Tailstock sleeve With inner Morse taper MK2
Sleeve adjustability 65 mm
Scale 1 mm
Thread cutting
With lead screw and change gear quadrant Right thread
Automatic longitudinal feed 0 – 250 mm/min
Change gear set for thread cutting Metric 0.25 - 6.0 mm - imperial 10 - 36 G/"