WABECO D4000 User manual

Bitte vor Inbetriebnahme lesen!
Bitte vor Inbetriebnahme lesen!
Operating Instructions
Lathes
With prismatic cast iron bed
D4000

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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
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
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 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, 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]

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Contents
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 Modifications 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. Specifications regarding the machine 13
4.1 Identification of the model 13
4.2 Noise emission declaration 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 18
and avoiding incorrect usage
6. Thread cutting and automatic feed 20
6.1 Thread cutting 20
6.2 Tumbler gear drive 21
6.3 Use of change gears 22
7. Maintenance 24
8. Lubrication of the machine 24
9. Readjusting the main spindle 26
10. Overload coupling 26
11. Readjustment of the bearing clearance of the lead screw 27
12. Tool skid – Transverse skid 27

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Contents
13. Tool skid – Longitudinal skid 29
14. Tailstock 30
15. 3 and 4 jaw lathe chuck 31
16. Operational faults and the elimination of such 32
17. Operating 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 – Transmission 41
18.5 Headstock – Tumbler gear 42
18.6 Bed with lead screw 44
18.7 Change gear quadrant 46
18.8 Tool skid – Transverse skid 48
18.9 Tool skid – Lock plate 50
18.10 Tool skid – Longitudinal skid 52
18.11 Tailstock 54
19. Circuit diagram 56
19.1 for 1.4 kW motor 56
19.2 Key for Circuit diagram 57
20. Shavings tank with spray protection wall (optional) 58
20.1 Setting up the shavings tank with spray protection wall 58
20.2 Mounting the shavings tank with spray protection wall on 59
tool machine cabinet (optional)
20.3 Drawing and legend 60
21. Coolant system (optional) 61
21.1 Setting up the coolant system 61
21.2 Mounting of the coolant system to the 61
tool machine cabinet (optional)
21.3 Safety regulations for the handling of cooling lubricant 63
21.4 Filling the coolant system 63
21.5 Operating the coolant system 64
21.6 Positioning the segmented coolant hose 65

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Contents
21.7 Controlling the flow of coolant using the coolant shut-off valve 65
21.8 Drawing and legend 66
22. Fixed bezel (optional) 68
22.1 Operating the fixed bezel 68
22.2 Drawing and legend 69
23. Tensioning bracket with milling machine table (optional) 70
23.1 Mounting the tensioning bracket with milling machine table to the lathe 70
23.2 Operating elements 71
23.3 Feed motion of the milling machine table 71
23.4 Adjustment of the dovetail guide 72
23.5 Alignment of the milling machine table 72
23.6 Lubrication of the tensioning bracket with milling machine table 72
23.7 Drawing and legend 73
24. Adjustable longitudinal stopper (optional) 75
24.1 Mounting of the adjustable longitudinal stopper 75
24.2 Drawing and legend 76
25. Collet chuck (optional) 77
25.1 Mounting the collect chuck 77
25.2 Drawing and legend 77
25.3 Installation and removal of collets 78

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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:
D4000
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

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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 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
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 recognized.
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.

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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.
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 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.

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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
Noise emission declaration in accordance with DIN EN ISO 3744
Emission values in idle
Emission noise 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)
With an emission noise level as of 80 dB (A) at the workplace
ear defenders must be worn

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4. Specifications regarding the machine
4.2.1 Technical data
Working areas
Distance between centers
350 mm
Centre height
100 mm
Swing diameter via guide
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, 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 centers
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 120 mm
Adjustability of the longitudinal skid 50 mm
Longitudinal skid can be swivelled by 360°
Max. turning steel height 16 mm
Tailstock with quick adjustment
Lateral adjustability of the tailstock upper ± 10 mm
Tailstock sleeve With inner Morse taper MK2
Sleeve adjustability 45 mm
Scale ring read accuracy 0.1 mm
Thread cutting
Tumbler gear drive For left-right thread
2 automatic longitudinal feeds 0.085 und 0.16 mm/U
Change gear set for thread cutting Metric 0.25 – 7.0 mm - imperial 10 - 40 G/"

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4. Specifications regarding the machine
4.4 Dimensions Front view
A 4 fixing holes M8 (20 mm deep)
4.5 Dimensions Side view
A 4 fixing holes M8 (20 mm deep)

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4. Specifications regarding the machine
4.6 Revolution selection
Select the spindle revolutions according to the material type of work piece diameter:
Small work piece diameter ⇒Relatively high revolutions
Large work piece 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:
Application example:
Thus, an aluminium work piece with a Øof 20 mm is to be turned with a cutting speed of 100 m/min.
Now, select from the potential revolutions, the one that comes closest to the ideal of 1592 rpm.
4.7 Diagram for reading off the revolutions
4000
3000
2000
1000
800
600
400
200
100
80
60
40
20
10
120
246 8 10 20 40 60 80 100 160 200
V
m/min
2500
1600
1250
800
500
250
mm
n1/min
Revolutions
Cutting speed (V) x 1000
Work piece diameter (d) x 3.14
100 x 1,000
20 x 3.14
100.000
62.8
1592 rpm
=
=

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4. Specifications regarding the machine
4.8 Revolution changer
The potentiometer can be used to infinitely 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

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4. Specifications 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 briefly 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, work piece 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 bezel.
■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 sufficiently.
■Set the bearing clearance and guides correctly.
Longitudinal turning
■For longitudinal turning, the turning steel moves parallel to the axis of the work piece.
■To rough, it is advantageous to use straight or curved turning steels.
■To finish, 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 skid 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.

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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 work piece).
Offset lateral lathe chisel (3)
■For longitudinal and face turning
■Is used for finishing (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 work pieces
■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 firmly.
■If the lever arm is too long, the lathe chisel will bend and spring back.
■The cutting edge will penetrate the work piece 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 work piece 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.
6
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1

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6. Thread cutting and automatic feed
6.1 Thread cutting
■The thread turning steel is a moulded turning steel with the profile 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 profile.
■In order to obtain the correct position of thread flanks to the work piece axis, place the grinding
gauge up against the work piece and use it to set the turning steel (Figure 1). To do this, push the
gauge up to both flanks of the turning steel, one after another.
Figure 1: Setting the thread turning steel
90°
■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 fitting different toothed wheel combinations, it is possible to cut metric and imperial right and left
threads.
■The different axis intervals of the toothed wheels can be set by swivelling 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 transverse skid out of the inroad otherwise
the flanks 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
work piece from pushing away.