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!