WABECO D4000 User manual

Operating Instructions
Lathes
With prismatic cast iron bed
D4000

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 recognized.
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:
■ 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ofcially
recognized 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, aluminum and only 2% are chemical materials, e.g. cable sleeves of electrical
cables,PCBs.
Ifyouhaveanydifculties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.
Disposing of the machine
wabeco-rs.de
WalterBlombachGmbH
42899 Remscheid
AmBlaffertsberg13
Germany
Phone +49(0)2191597-0
Fax +49(0)2191597-42
E-Mail[email protected]

3
Index
Declaration of conformity for D4000 6
1. Important safety notes 7
1.1 Intendeduse 7
1.2 Improperandincorrectuse 7
1.3 Modicationstothemachine 7
1.4 Safetyregulationsforproperuse 7
1.5 Safetyfeatures 10
1.6 Explanations of the symbols 10
2. Delivery and set up 11
2.1 Transporting the machine 12
3. Putting into operation 13
4. Specications regarding the machine 13
4.1 Identicationofthemodel 13
4.2 Declarationofnoiselevels 13
4.3 Technicaldata 14
4.4 Dimensionsfrontview 15
4.5 Dimensionssideview 15
4.6 Revolution selection 16
4.7 Diagramforreadingofftherevolutions 16
4.8 Revolutionchanger 17
4.9 Electrical equipment 18
5. Achieving optimum results and avoiding incorrect usage 18
6. Thread cutting and automatic feed 20
6.1 Thread cutting 20
6.2 Tumbler gear 21
6.3 Useofchangegears 22
7. Maintenance 24
8. Lubrication of the machine 24
9. Re-adjusting the main spindle 26
10. Overload clutch 26
11. Re-adjustment of the bearing clearance of the lead screw 27
12. Tool slide – cross slide 27
13. Tool slide – longitudinal slide 29
14. Tailstock 30
15. 3- and 4-jaw lathe chuck 31

4
Index
16. Operational faults and the elimination of such 32
17. Control elements 35
18. Drawings and legends 36
18.1 Electronicconsole 36
18.2 Protectivehood,drive1.4kWmotor 39
18.3 Headstock 40
18.4 Headstock–intermediategear 41
18.5 Headstock–tumblergear 42
18.6 Bedwithleadscrew 44
18.7 Changegearquadrant 46
18.8 Toolslide–crossslide 48
18.9 Toolslide–lockplate 50
18.10 Toolslide–longitudinalslide 52
18.11 Tailstock 54
19. Circuit diagram 56
19.1 For1.4kWmotor 56
19.2 Legendforcircuitdiagram 57
20. Chip- and coolant tray with splash guard (optional) 58
20.1 Settingupthechip-andcoolanttraywithsplashguard 58
20.2 Mountingthechip-andcoolanttraywithsplashguardon 59
machine base cabinet (optional)
20.3 Drawingandlegend 60
21. Coolant unit (optional) 61
21.1 Setting up the coolant unit 61
21.2 Mountingofthecoolantunittothemachinebasecabinet(optional) 61
21.3 Safetyregulationsforthehandlingofcoolinglubricant 63
21.4 Fillingthecoolantunit 63
21.5 Operatingthecoolantunit 64
21.6 Positioningthesegmentedcoolanthose 65
21.7 Controllingtheowofcoolantusingthecoolantshut-offvalve 65
21.8 Drawing and legend 66
22. Fixed stay (optional) 68
22.1 Operatingthexedstay 68
22.2 Drawing and legend 69

5
Index
23. Clamping angle with milling attachment (optional) 70
23.1 Mountingtheclampinganglewithmillingattachmenttothelathe 70
23.2 Controlelements 71
23.3 Feedmotionofthemillingattachment 71
23.4 Adjustmentofthedovetailguide 72
23.5 Alignmentofthemillingattachment 72
23.6 Lubricationoftheclampinganglewithmillingattachment 72
23.7 Drawingandlegend 73
24. Adjustable longitudinal stop (optional) 74
24.1 Mountingoftheadjustablelongitudinalstop 74
24.2 Drawingandlegend 75
25. Collet chuck (optional) 76
25.1 Mountingthecollectchuck 76
25.2 Drawingandlegend 76
25.3 Installationandremovalofcollets 77

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-42871Remscheid Postfach120161  Telephone:(02191)597-0 Fax:(02191)597-42
 D-54673Neuerburg WABECOStr.1-10  Telephone:(06564)9697-0 Fax:(06564)9697-25
that the following named
Universal lathe
Type:
D4000
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
Inordertofull/implementtherequirementsofthedirectivesnamedabove,thealready
published and applicable standards were drawn upon:
EN ISO 12100:2010
DIN EN 60204-1:2007
DIN EN ISO 23125:2015
Proxyforthecompilationofthetechnicaldocumentationistheoperationalheadofthe
abovenamedmanufacturer,MrChristophSchneider.
D-54673Neuerburg2018
________________________________
Placeanddateofissue
________________________________
Operational head Christoph Schneider

7
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 Modications to the machine
Forreasonsofsafety,itisforbiddenfortheusertomakemodicationsofanytypetothelathe.
WalterBlombachGmbHacceptsnoresponsibilityforpropertydamageandpersonalinjurycausedas
aresultofanymodicationstothelathebytheuserthathavenotexpresslybeenauthorized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 instruc-
tions, and in particular, the safety notes prior to putting the machine into operation.
Inordertofulltheserequirements,theseoperatinginstructionsmustaccompanythemachinethroug-
hout 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.

8
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noticationsonthemachineareobserved
and that the signs are kept in a legible state.
5. Do not work without goggles.
6. Wearclosettingclothingand,ifyouhavelonghair,wearahairnet.Donotwearloosetting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.

9
1. Important safety notes
1.4 Safety regulations for proper use
19. Onlyhaverepairscarriedoutbyaqualiedspecialist!Repairworkmayonlybecarriedoutby
personswhoarequalied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insufcient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 workpieces may never be changed when the machine is running.
25. Do not brake workpieces and bush using your hand or another object.
26. Neverleavethechuckkeytted(evenwhennotinoperation).
27. Payattentiontothespreadofthelathechuck.
28. Themaximumrevolutionrangespecied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rmlytensioned,atthecorrectheightandasshortaspossible.
34. Do not measure at the rotating workpiece (risk of accident, measuring tools will be damaged).
35. Whenworkingbetweenthetips,checkthelockingleverofthetailstockforrm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 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.

10
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
TheON/OFFswitchistted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 unexpec-
ted motion of the spindle.
■Emergency off switch
The emergency off switch acts to quickly stop the machine.
■Overload protection
Themachineistted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ameasurednoiselevelof80dB(A)attheworkpla-
ce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
maintenancework!
Caution:
Dangerouselectricvoltage!

11
2. Delivery and set up
The machine is packed with care at the factory.
The following should be checked after delivery:
■whether the packaging shows damages to be reported or
■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 recognized.
Themachinemustbesetuponasuitable,evenandrmsurface.
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
■ thereissufcient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 unit.

12
2.1 Transporting the machine
We recommend two people to lift the machine, using the positions shown (1).
Todothis,asufciently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.
Due to the weight of the machine it is advisable to lift the machine by crane, if this is possible. To lift, wrap
suitable lashing (2) as shown around the two outer struts of the ribbing of the machine bed.
Whenlifting,payattentiontoanergonomicstanceandsufcientsafety!
2. Delivery and set up
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.
1
1
2

13
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sufcientcoolantfortheoperationofacoolantunit(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. Specications regarding the machine
4.1 Identication of the model
The precise model designation of your machine can be found on the type plate attached to the machine.
4.2 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
at50% =70.3dB(A
at 100 % =78.2dB(A)
Sound power level
at50% =76.8dB(A)
at 100 % =86.6dB(A)
Atanemissionsoundpressurelevelfrom80dB(A)andaboveattheworkplace
ear protection is required

14
Working range
Center distance 350mm
Center height 100 mm
TurningØabovetheguideways 200 mm
Bedwidth 120 mm
Main drive motor
Nominalvoltage 230V
Nominalfrequency 50/60Hz
Nominalperformanceofthespindlemotor 1.4 kW
Spindlerevolutions,innite 30-2300rpm
Machine precision
True running accuracy of spindle nose 0.005mm
Cylindrical turning to 100 mm cantilevered 0.01 mm
Cylindricalturningwithanishingcutto300mm
between the centers 0.015mm
Headstock
Mainspindlebore Ø20mm
Taper in main spindle MT3
Mainspindlenose accordingtoDIN6350
Tool slide
Travel of cross slide 120 mm
Travel of longitudinal slide 50mm
Longitudinal slide can be swiveled through 360°
Max.heightofturningtools 16 mm
Tailstock with quick adjustment
Lateral adjustability of tailstock upper part ± 10 mm
Tailstock sleeve withaninternalMT2morsetaper
Travel of tailstock sleeve 45mm
Scale ring reading accuracy 0.1 mm
Thread cutting
Tumbler gear forleft-andright-handthreads
2 automatic longitudinal feeds 0.085and0.16mm/rev
Change gear set for thread cutting metric0.25-7.0mm-inch10-40TPI
4. Specications regarding the machine
4.3 Technical data

15
4. Specications regarding the machine
4.4 Dimensions front view
4.5 Dimensions side view
A4xingholesM8(20mmdeep)
A4xingholesM8(20mmdeep)
14571
375100
375
45
63609
860
A
AA
14571
375100
375
45
63609
860
A
A A

16
4. Specications regarding the machine
4.6 Revolution selection
4.7 Diagram for reading off the revolutions
Select the spindle revolutions according to the material type of workpiece diameter:
Small workpiece diameter ⇒ Relatively high revolutions
Large workpiece diameter ⇒ Low revolutions
Revolutions and diameter give the cutting speed.
In the event of a specified cutting speed, the required spindle revolutions can be calculated as follows:
Revolutions(n)=Cuttingspeed(V)x1000
Workpiecediameter(d)x3.14
Application example:
Thus,analuminumworkpiecewithaØof20mmistobeturnedwithacuttingspeedof100m/min.
100 x 1.000
20x3.14 ˭
100.000
62.8 ˭1592rpm
Now,selectfromthepotentialrevolutions,theonethatcomesclosesttotheidealof1592rpm.

17
4. Specications regarding the machine
4.8 Revolution changer
Thepotentiometercanbeusedtoinnitelyadjusttherevolutionsoftheworkingspindlefrom150-2300
rpm (2nd setting = preset at the factory).
Ifthelowerrevolutionsof30-490rpm(1stsetting)arerequired,thedrivebeltmustbeapplied.Todo
this, proceed as follows:
1. Open the gear cover hood by undoing the safety screw with the supplied special key.
2. Undothehexagonalnut(3)andthisloosenthedrivebelt(1+2).
3. Turntheclampingscrew(4)anti-clockwiseinsuchawaythatthedrivebelt(1)canbeplacedon
theothertransmissionsettingofthebeltpulley(5+6).
4. Totensionthedrivebelt(1+2)tightentheclampingscrew(4)inaclockwisedirectioninsucha
waythatthedrivebelt(1+2)cannotsliponthebeltpulley.
5. Tightenthehexagonalnut(3)backupagain.
6. Close the drive cover hood again and secure with the safety screw.
Setting on the potentiometer 1st setting rpm 2nd setting rpm
0% 30 150
10% 35 155
20% 50 220
30% 90 450
40% 150 850
50% 200 1050
60% 290 1500
70% 350 1900
80% 400 2050
90% 460 2200
100% 490 2300
1
2
6
5
4
3

18
4. Specications regarding the machine
4.9 Electrical equipment
Themaindrivemotor(singlephaseseries-woundmotor)issuppliedalreadyinstalled
■ ThemainspindledrivehasanON/OFFswitchwithunder-voltagetrigger.
■ Inorderforthemachinetostart,theturnswitchforforwards-reversemustbesettotherequired
direction of rotation.
■ ThenswitchonattheON/OFFswitch.
■ TheON/OFFswitchmustalsobeswitchedonagainafterthepowerisinterrupted.
■ Tochangethedirectionofrotationofthemaindrivemotor,theturnswitchmustbrieyrestatthe0
position to allow the relays on the control board enough time to switch.
■In the event of the main drive motor being overloaded, it will switch itself off automatically. The
main drive motor can only be switched back on again after a short waiting period.
5. Achieving optimum results
and avoiding incorrect usage
■ Useofsuitableprocessingtools.
■Adaptation of revolution setting and feed to the material, workpiece and tool.
■Tension tools as far into the tool holder as possible (short projecting length).
■Tension turning element as far into the chuck as possible (short projecting length).
■Support length pieces with a tailstock or stay.
■The use of coolant and lubrication to increase the durability of the tool, improve surface quality and
accuracy.
■Clamp processing tools and turning elements on a clean clamping surface.
■ Lubricatemachinesufciently.
■Set the bearing clearance and guides correctly.
Longitudinal turning
■For longitudinal turning, the turning steel moves parallel to the axis of the workpiece.
■To rough, it is advantageous to use straight or curved turning steels.
■ Tonish,usesharporwideturningsteels.
Face turning
■The processing of end planes is referred to as face turning.
■When face turning, the turning steel is moved at right angles to the rotating axis of the turning
element. The tool slide should be locked when doing so.
■The main cutting edge of the turning steel is to be set precisely to the center so that the turning
element center has no nose.
■The curved turning steel is used for face turning.

19
5. Achieving optimum results
and avoiding incorrect usage
Curved lathe chisel right (2) and left (1)
■For longitudinal and face turning.
■This is designed to remove as much material as possible in a short time (without paying attention
to the surface created on the workpiece).
Offset lateral lathe chisel (3)
■For longitudinal and face turning.
■ Isusedfornishing(creatingacleansurface).
External thread lathe chisel (4)
■is used for cutting external threads.
Narrow square-nose cutting tool (5)
■is used to cut grooves and cut off workpieces.
■Attention should be paid to the precise height of the center of the turning steel.
■Work with low revolutions and cool the tool (cooling via drilling oil or emulsion: acts as lubrication
and removal of shavings).
■The cutting steel is to be tensioned as short as possible and at a right angle to the rotational
axis.
Inner lathe chisel (6)
■is used for hollowing out drilled holes.
■Tension as short as possible to prevent the occurrence of turning steel vibrations (untidy surface).
■ Asaresultoftheforcesexertedontheturningsteel,thesteelmustbeshortandsecuredrmly.
■If the lever arm is too long, the lathe chisel will bend and spring back.
■The cutting edge will penetrate the workpiece unevenly and result in a bumpy surface.
■The turning steel is to be aligned with the center of the turning element.
■The checking of the height to the center of the workpiece is carried out with the help of the turning
center point in the tailstock. The height position of the turning steel is achieved by adding even
sheets.

20
6. Thread cutting and automatic feed
6.1 Thread cutting
■ Thethreadturningsteelisamouldedturningsteelwiththeproleofthethreadtobecut.
■It is ground according to templates (Figure 1) and must be set precisely to the center of the work-
pieceotherwisetherewillbeadistortioninthethreadprole.
■ In order to obtain the correct position of thread anks to the workpiece axis, place the grinding
gauge up against the workpiece and use it to set the turning steel (Figure 1). To do this, push the
gaugeuptobothanksoftheturningsteel,oneafteranother.
■The feed of the thread turning steel is carried out via the lead screw and must match the thread
gradient.
■The change gears belonging to the accessories create the connection between the feed drives
and the lead screw.
■ Byttingdifferenttoothedwheelcombinations,itispossibletocutmetricandinchright-andleft-
hand threads.
■The different axis intervals of the toothed wheels can be set by swiveling the quadrant and
adjusting the quadrant bolt.
Feed:
■The feed is switched on using the switch lever on the lock plate.
■The feed must always be switched on in order for the turning steel to return to the same position
when carrying out multiple cutting procedures.
■After completing the cut, bring the turning steel with the cross slide out of the inroad otherwise the
anksandcuttingedgeswillbedamaged.
■Then return the turning steel to the starting position by changing the direction of rotation of the motor
viatheturnswitchforforwards-reverse.
■ Itisgoodifthethreadendhasa4-5mmwideclearancemilledinordertobetterremovethethread
steel out of the way.
In the event of a long thread diameter, the turning center point should always be used to prevent the
workpiece from pushing away.
Figure 1: Setting the thread turning steel