WABECO D4000 E User manual

Operating instructions
Universal Mechanic Lathes
D4000 E
CC-D4000 E
Walter Blombach GmbH
Tool and Machine Factory
D-42899 Remscheid - Am Blaffertsberg 13 - Phone.: [phone] - Fax: [phone] – 40 - E-Mail: [e-mail]
D-54673 Neuerburg - WABECO Str. 1-10 - Phone.: [phone] - Fax: [phone] - E-Mail: [e-mail]
www.wabeco-remscheid.de

2
Index
EC – Conformity Declaration 4
1. Technical Data 6
2. Drawing and list of parts 7
2.1 Lubricating plan 7
2.2 Arrangement of take-up gears for a 1 mm thread pitch (slope) 8
2.3 Diagram for reading off speed 9
2.4 Position of tumbler gear when cutting LH thread 10
2.5 Position of take-up gears for automatic feed 11
2.6 Operating elements 12
2.7 Headstock with gear and tumbler gear 14
2.7.1 Headstock 14
2.7.2 Gear 14
2.7.3 Tumber gear 14
2.8 Bed with leading spindle drive and take-up gear cutter 16
2.8.1 Bed with leading spindle drive 16
2.8.2 Take-up gear cutter 16
2.9 CNC control drive Z-axis 18
2.10 Tool carriage 20
2.10.1 Saddle apron with cross slide 20
2.10.2 Top slide 21
2.11 CNC control drive X-axis 23
2.12 Headstock 25
2.13 Motor frame 27
3. Circuit diagram 29
4. Delivery and installation 30
5. Conditions for best working results 31
6. Starting-up and maintenance 31
6.1 Maintenance 31
6.2 Starting-up 31
6.3 Lubrication of the machine 32
6.4 Guidelines for the periodical maintenance of the machine 32
7. Safety instructions 32
8. Description of the machine 33
8.1 Labelling 33
9. Description of modules 34
9.1 Structural features 34
9.2 Spindle head 34
9.2.1 Main spindle 34
9.2.2 Electrical parts 35
9.2.3 Change of speed 35

3
Index
9.2.4 Speed transmission from main spindle to leadscrew 35
9.2.5 Tumbler wheel adjustment 36
9.2.6 Protective cover for chuck 36
9.3 Bed with leadscrew drive 36
9.3.1 Overload coupling 36
9.3.2 Setting the bearing play on the leadscrew 36
9.4 Tooling carriages 37
9.4.1 Cross slide 37
9.4.2 Top slide 37
9.5 Tailstock 38
10. Applications 39
10.1 Longitudinal and transverse turning 39
10.2 Thread cutting and automatic feed 40
10.2.1 Thread cutting 40
10.2.2 Application of change gears 41
10.2.3 Altering the feeds or thread pitches 42
10.2.4 LH thread 43
11. Three-jaw chuck and four-jaw chuck 44
12. Tool holder with conical sleeve 44
13. Square turret head 45

4
EC – Conformity Declaration
In the name of the manufacturer
Walter Blombach GmbH
Tool and Machine Factory
based in Remscheid and Neuerburg
D-42871 Remscheid - Postfach 12 01 61 - Phone: [phone] - Fax: [phone] - 40
D-54673 Neuerburg - WABECO Str. 1-10 - Phone: [phone] - Fax: [phone]
We hereby declare that the universal lathes specified below
Universal mechanic lathe Typ:
D4000E
meet the following regulation requirements for standard serie production
- EC directive for machines EEC 91/68 and 89/392
- EC low voltage directive 72/23/EEC
In order to meet / implement the requirements of the above mentioned directives, the following appli-
cable and previously published standards have been adhered to
EN 292-1
EN 292-2
EN292-2 Enclosure I
EN 294
EN 349
EN 418
EN 60204-1
D-54673 Neuerburg
________________________________
City
Signature

5
Outlay
Dear customer!
Congratulations on choosing the WABECO Universal Lathe. We have taken great care in its
manufacture and we have given it a thorough quality control test. These operating instructions are
to help you to work with it safely and properly.
After unpacking the machine please check to see if any kind of damage has occurred during trans-
portation. Any complaints must be made immediately. Complaints made at a later date cannot be
accepted.
If you have any questions or need any spare parts, please quote the machine number lo-
cated on the front of the motor).
Wir können Ihnen wahlweise unsere Bedienungsanleitungen und Prospekte
in englischer und französischer Sprache kostenlos zusenden.
We are able to send you free of charge our Operating Instructions and leaflets
in French and/or English translation.
Nous avons la possibilité de vous donner nos Instructions de Service et pros-
pectus aussi en traduction francaise et/ou anglaise, sans frais.

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1. Technical Data
Working range
Centre distance.......................................................... 350 mm
Centre height.............................................................. 100 mm
Largest turning diameter over bed.............................. 200 mm
Largest turning diameter over slide............................ 120 mm
Work spindle
Drive output................................................................ 1,4 Kw, 220V, 50Hz
Infinetely variable spindle speed................................. 45 – 2300
Spindle bore............................................................... 20 mm
Cone in spindle nose Cone 3
Cross table
Cross table range of displacement............................. 100 mm
Turning carriage´s range of displacement.................. 50 mm
Turning carriage´s range of displacement.................. 360°
Max. height of turning tools ........................................ 16 mm
Guideways
Longitudinal support................................................... Dovetail guide and adjustment rails
Cross support............................................................. Dovetail guide and adjustment rails
Chips and dirt stripper ................................................ Protection of the guides
Tailstock
Tail spindle´s range of displacement.......................... 45 mm
Tail spindle´s hole bore .............................................. Cone 2
Lateral displacement of the tailstock
to both sides............................................................... ± 10 mm
Screw cutting attachment
Advance..................................................................... 0,085 and 0,16 mm/min
Thread pitch ...............................................................
- metric....................................................................... 0,4 - 3,0 mm
- inch .......................................................................... 10 - 32 thead per inch
Noise values according DIN 45635 - part 1
Emission data
No-load running LpA = 63 dB(A)
Load running LpA = 67 dB(A)
- Subject to technical alterations -

7
2. Drawing and list of parts
2.1 Lubricating plan
1
all 8 working hours
2
all 8 working hours
2. Drawing and list of parts

8
2.2 Arrangement of take-up gears for a 1 mm thread pitch (slope) (LH thread)
2. Drawing and list of parts

9
2.3 Diagram for reading off speed
4000
3000
2000
1000
800
600
400
200
100
80
60
40
20
10
120
246810 20 40 60 80 100 160 200
V
m/min
2500
1600
1250
800
500
250
mm
n 1/min
Diagram
I II
0% 75 370
10% 80 380
20% 105 500
30% 170 850
40% 250 1250
50% 300 1500
60% 340 1700
70% 385 1950
80% 440 2200
90% 460 2300
100% 460 2300
2. Drawing and list of parts

10
2.4 Position of tumbler gear when cutting LH thread
2. Drawing and list of parts
2.5 Position of take-up gears for automatic feed
Tumbler wheel
Clamping
screw

11
2. Drawing and list of parts
2.6 Operating elements

12
1. Potentiometer turning knob for choosing the speed of the driving electric motor
2. Emergency OFF switch
3. Reversing switch for changing direction of turn – main spindle
4. Master switch with undervoltage release
5. Opening and closing of clasp nut
6. Chuck handwheel für longitudinal support
7. Clamping lever for tool clamping plate
8. Ball-ended crank for adjusting of cross slide
9. Chuck for quick adjusting of cross slide
10. Clamping screw for clamping of tool carriage
11. Ball-ended crank for adjusting of top slide
12. Chuck handwheel for fastening the centre sleeve of tailstock
13. Clamping lever for fastening the tailstock on guides
14. Ball-ended crank for adjusting the centre sleeve of tailstock
2. Drawing and list of parts
2.6 Operating elements

13
2. Drawing and list of parts
2.7 Headstock with gear and tumbler gear
2.7.1 Headstock

14
Part-No. Pcs. Order-No. Designation
1 2 10400101 Tapered roller bearing
4 1 10400104 Headstock
5 1 10400105 Flange, front
6 1 10400106 Work spindle
7 1 10400107 Oil wiper ring
8 1 10400108 Feather key
9 1 10400109 Flange, rear
10 2 10400110 Distance ring
11 1 10400111 Belt pulley
12 1 10400112 Belt pulley
13 1 10400113 Adjusting nut
14 3 10400114 Countersunk screw
15 2 11810005 Lubricating nipple
16 7 10400116 Hexagon socket screw
17 1 10400117 Belt short for gear
18 1 10400118 Belt
19 1 10400119 Cover plate
20 1 10400120 Knurled nut
21 1 10400121 Threaded pin
22 2 10400122 Hexagon socket screw
2.7.2 Gear
Part-No. Pcs. Order-No. Designation
23 1 10400123 Belt pulley
24 2 10400124 Ball bearing
25 1 10400125 Bushing
26 1 10400126 Axis
27 1 10400127 Circlip
28 1 10400128 Disc
29 1 10400129 Handle
30 1 10400130 Disc
31 1 10400131 Nut
2.7.3 Tumbler gear
Part-No. Pcs. Order-No. Designation
32 2 10400132 Belt pulley
33 2 10400133 Ball bearing
34 2 10400134 Bolt
35 1 10400135 Handle
36 1 10400136 Clamping bolt
37 1 10400137 Fixing bolt
38 1 10400138 Bushing
39 1 10400139 Feather key
40 1 10400140 Belt pulley Z52
41 1 10400141 Belt pulley Z16
42 2 10400142 Flanged wheel
2. Drawing and list of parts
2.7 Headstock with gear and tumbler gear
43 1 10400143 Disc
44 1 11700053 Nut
45 1 11810009 Lubricating nipples
46 2 11700077 Headless pin

15
12
2. Drawing and list of parts
2.8 Bed with leading spindle drive and change gear quadrant
2.8.1 Bed with leading spindle drive
Part-No. Pcs. Order-No. Designation

16
1 1 10400201 Toothed racket
3 1 10400203 Bed
4 1 10400204 Supporting bearing, front
5 1 10400205 Bushing
6 1 10400206 Leading spindle
7 1 10400207 Supporting bearing, rear
8 2 10400208 Thrust block, loose
10 1 10400210 Bushing
11 4 10400211 Hexagon socket screw
12 6 10400212 Hexagon socket screw
13 2 11810005 Lubricating nipple
14 2 10400214 Nut
17 1 10400217 Disc
18 2 10400218 Nut
19 2 10400219 Hexagon socket screw
2.8.2 Take-up gear cutter
Part-No. Pcs. Order-No. Designation
1 1 10400301 Take-up gear cutter
2 1 10400302 Shearing bushing
3 1 10400303 Feather key of shearing bushing
4 3 10400304 Belt pulley Z48
5 1 10400305 Bushing
6 2 10400306 Disc
7 2 10400307 Disc
8 1 10400308 Take-up gear bolt
9 2 10400309 Bushing
10 2 10400310 Feather key for bushing
11 2 10400311 Toothed belt
12 2 10400312 Toothed belt pulley Z14
13 1 10400313 Take-up gear bolt
14 2 10400314 Disc
15 2 11700053 Nut
16 2 11810009 Lubricating nipple
17 2 11700054 Square nut
2. Drawing and list of parts
2.8 Bed with leading spindle drive and take-up gear cutter

17
2. Drawing and list of parts
2.9 CNC control drive Z-axis
Part-No. Pcs. Order-No. Designation
32 1 Belt pulley Z30
33 1 Threaded pin
34 1 Motor sheet metal
35 2 Earthing screw
37 1 Motor housing

18
38 1 Step motor
39 4 Washer
40 4 Earthing screw
41 4 Hexagon nut
42 1 Lid for motor housing
43 4 Earthing screw
44 1 Belt pulley Z12
45 1 Zylindrical pin
46 2 Washer for tooth wheel
47 2 Circlip
48 1 Toothed belt
49 1 Protective cover
50 2 Nut
2. Drawing and list of parts
2.9 CNC control drive Z-axis

19
2. Drawing and list of parts
2.10 Tool carriage
2.10.1 Saddle apron with cross slide
Part-No. Pcs. Order-No. Designation
1 1 10400401 Lower part of cross slide
2 1 10400402 Nut
3 1 10400403 Disc
4 1 10400404 Hexagon bolt
5 1 10400405 Upper part of cross slide

20
6 1 10400406 Adjustment rail
7 2 10400407 Felt
8 2 10400408 Felt
9 2 10400409 Felt clamp
10 2 10400410 Felt clamp
11 14 10400411 Hexagonal socket bolt
12 6 10400412 Hexagon bolt
13 1 10400413 Saddle apron
14 2 10400414 Hexagonal socket bolt
15 1 10400415 Cleap holder
16 2 10400416 Clasp nut
17 2 10400417 Pin
18 2 10400417 Guide rail
19 1 10400419 Feather key clasp holder
20 1 10400420 Switch lever
21 1 10400421 Disc
22 1 10400422 Flange
23 1 10400423 Liner
24 2 11810005 Lubricating nipple
25 9 10400425 Hexagonal socket bolt
26 1 10400426 Pinion
27 2 10400427 Scale support
28 4 10400428 Thrust piece scale support
29 4 10400429 Threaded pin
30 1 10400430 Hand wheel
31 2 10400431 Pin
32 2 11810004 Ball
33 2 10400433 Scale ring
34 1 10400434 Flange
35 1 10400435 Liner
36 1 10400436 Take-up gear
37 1 10400437 Disc
38 1 10400438 Clamping piece
39 1 10400439 Hexagonal socket bolt
40 1 10400440 Guide piece
41 4 10400441 Hexagonal socket bolt
45 3 11700055 Threaded pin
46 1 10400446 Guide rail
47 1 10400447 Guide rail
48 3 10400448 Threaded pin
2. Drawing and list of parts
2.10 Tool carriage
2.10.1 Saddle apron with cross slide
Part-No. Pcs. Order-No. Designation
52 1 10400452 Washer
53 2 11850002 Feather
54 1 10400454 Spindle bearing
55 2 10400455 Deep groove ball bearing