WABECO F1200 high speed User manual

Operating instructions
Milling machines
CNC milling machines
with dovetail guides
F1200 F1200 hs F1210 F1210 hs
F1200-C F1200-C hs F1210-C F1210-C hs
CC-F1200 CC-F1200 hs CC-F1210 CC-F1210 hs

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 09/2014
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 your 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, Germany
Am Blaffertsberg 13
Germany
Phone [phone]
Fax [phone]
Email [email protected]

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Contents
Declaration of conformity for F1200 - F1200 hs - F1210 - F1210 hs 8
Declaration of conformity for F1200-C - F1200-C hs - F1210-C - F1210-C hs 9
Declaration of conformity for CC-F1200 - CC-F1200 hs - CC-F1210 - 10
CC-F1210 hs
1. Important safety notes 11
1.1 Intended use 11
1.2 Improper and incorrect use 11
1.3 Modifications to the machine 11
1.4 Safety regulations for proper use 11
1.5 Safety features 14
1.5.1 for all milling machines 14
1.5.2 for milling machines with CNC control assembly and CNC 14
1.5.3 for CNC milling machines 14
1.6 Explanations of the symbols 15
2. Delivery and set up 15
2.1 Transporting the machine 16
3. Putting into operation 17
3.1 for all milling machines 17
3.2 for all CNC milling machines 17
3.2.1 Setting up and connecting the control computer 17
4. Specifications regarding the machine 18
4.1 Identification of the model 18
4.2 Noise emission declaration F1200 - F1200 hs - F1210 - F1210 hs 18
4.2.1 Technical data for F1200 - F1200 hs 19
4.2.2 Dimensions of F1200 with 1.4 kW motor 20
4.2.3 Dimensions of F1200 hs with 2.0 kW motor 21
4.2.4 Technical data for F1210 - F1210 hs 22
4.2.5 Dimensions of F1210 with 1.4 kW motor 23
4.2.6 Dimensions of F1210 hs with 2.0 kW motor 24
4.3 Noise emission declaration 25
F1200-C - F1200-C hs - F1210-C - F1210-C hs
4.3.1 Technical data for F1200-C - F1200-C hs 26
4.3.2 Dimensions of F1200-C 27
4.3.3 Dimensions of F1200-C hs 28
4.3.4 Technical data for F1210-C - F1210-C hs 29
4.3.5 Dimensions of F1210-C 30
4.3.6 Dimensions of F1210-C hs 31

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Contents
4.4 Noise emission declaration 32
CC-F1200 - CC-F1200 hs - CC-F1210 - CC-F1210 hs
4.4.1 Technical data for CC-F1200 - CC-F1200 hs 33
4.4.2 Dimensions of CC-F1200 34
4.4.3 Dimensions of CC-F1200 hs 35
4.4.4 Technical data for CC-F1210 - CC-F1210 hs 36
4.4.5 Dimensions of CC-F1210 37
4.4.6 Dimensions of CC-F1210 hs 38
4.5 Revolution setting 39
4.6 Electrical equipment 1.4 kW motor 39
4.7 Electrical equipment 2.0 kW motor 40
5. Achieving optimum results 40
and avoiding incorrect usage
6. Fitting and removing the tools 42
7. Installation and removal of collets 44
7.1 Installation 44
7.2 Removal 44
8. Swivelling the milling head 45
9. Drill stroke - depth stop 46
10. Feed motions of the x, y and z axes 47
11. Adjustment of the spindle nuts with trapezoidal-threaded spindle 49
11.1 x and y axes 49
11.2 z-axis 50
12. Adjustment of the dovetail guides 51
13. Maintenance 52
14. Lubrication of the machine 52
15. Operational faults and the elimination of such 54
16. Operating elements 57
16.1 Milling machines F1200 - F1210 with 1.4 kW motor 57
16.2 Milling machines F1200 hs - F1210 hs with 2.0 kW motor 58
16.3 Milling machines F1200-C - F1210-C with 1.4 kW motor 59
16.4 Milling machines F1200-C hs - F1210-C hs with 2.0 kW motor 60
16.5 CNC milling machines CC-F1200 - CC-F1210 with 1.4 kW motor 61
16.5.1 Switch cover on CNC operating console 62
16.6 CNC milling machines CC-F1200 hs - CC-F1210 hs with 2.0 kW motor 63
16.6.1 Switch cover on CNC operating console 64

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Contents
17. Drawings and legends 65
17.1 Protective hood 65
17.2 Electronic hood with 1.4 kW motor 66
17.2.1 F1200 - F1210 - F1200-C - F1210-C 66
17.2.2 CC-F1200 - CC-F1210 68
17.3 Milling machine head with 1.4 kW motor 70
17.4 Milling machine head with 2.0 kW motor 72
17.5 Z-stand with vertical skid with trapezoidal-threaded spindle 76
17.6 Spindle z-axis with trapezoidal-threaded spindle 78
17.6.1 F1200 - F1200 hs - F1210 - F1210 hs 78
17.6.2 F1200-C - F1200-C hs - F1210-C - F1210-C hs - 80
CC-F1200 - CC-F1200 hs - CC-F1210 - CC-F1210 hs
17.7 Lateral drive for z-axis with trapezoidal-threaded spindle 82
17.8 Cross-slide support with trapezoidal-threaded spindle 84
17.9 Spindle x-axis with trapezoidal-threaded spindle 86
17.9.1 F1200 - F1200 hs - F1210 - F1210 hs 86
17.9.2 F1200-C - F1200-C hs - F1210-C - F1210-C hs - 88
CC-F1200 - CC-F1200 hs - CC-F1210 - CC-F1210 hs
17.10 Spindle y-axis with trapezoidal-threaded spindle 90
17.10.1 F1200 - F1200 hs - F1210 - F1210 hs 90
17.10.2 F1200-C - F1200-C hs - F1210-C - F1210-C hs - 92
CC-F1200 - CC-F1200 hs - CC-F1210 - CC-F1210 hs
17.11 Z-stand with vertical skid with ball screw spindle 94
17.12 Spindle z-axis with ball screw spindle 96
17.12.1 F1200 - F1200 hs - F1210 - F1210 hs 96
17.12.2 F1200-C - F1200-C hs - F1210-C - F1210-C hs - 98
CC-F1200 - CC-F1200 hs - CC-F1210- CC F1210 hs
17.13 Lateral drive for z-axis with ball screw spindle 100
17.14 Cross slide support with ball screw spindle 102
17.15 Spindle x-axis with ball screw spindle 104
17.15.1 F1200 - F1200 hs - F1210 - F1210 hs 104
17.15.2 F1200-C - F1200-C hs - F1210-C - F1210-C hs - 106
CC-F1200 - CC-F1200 hs - CC-F1210 - CC-F1210 hs
17.16 Spindle y-axis with ball screw spindle 108
17.16.1 F1200 - F1200 hs - F1210 - F1210 hs 108
17.16.2 F1200-C - F1200-C hs - F1210-C - F1210-C hs - 110
CC-F1200 - CC-F1200 hs - CC-F1210 - CC-F1210 hs

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Contents
17.17 End switch for x-axis 112
17.17.1 F1200-C - F1200-C hs - F1210-C - F1210-C hs - 112
CC-F1200 - CC-F1200 hs - CC-F1210 - CC-F1210 hs
17.18 End switch for y-axis 112
17.18.1 F1200-C - F1200-C hs - F1210-C - F1210-C hs - 112
CC-F1200 - CC-F1200 hs - CC-F1210 - CC-F1210 hs
17.19 End switch for z-axis 113
17.19.1 F1200-C - F1200-C hs - F1210-C - F1210-C hs - 113
CC-F1200 - CC-F1200 hs - CC-F1210 - CC-F1210 hs
17.20 Operating console for 1.4 kW motor 114
17.21 Operating console for 2.0 kW motor 118
17.22 Bracket arm for operating console 122
17.23 Industrial monitor and folio keyboard 124
17.23.1 Industrial monitor and folio keyboard for 1.4 kW motor 126
17.23.2 Industrial monitor and folio keyboard for 2.0 kW motor 128
17.24 Bracket arm for operating console with industrial monitor and folio keyboard 130
18. Circuit diagram 131
18.1 for 1.4 kW motor 131
18.2 for 1.4 kW motor and safety cabin 132
18.3 Industrial monitor and folio keyboard for 1.4 kW motor 133
18.4 for 2.0 kW motor 134
18.5 for 2.0 kW motor and safety cabin 135
18.6 Industrial monitor and folio keyboard for 2.0 kW 136
18.7 Multiphase motor with end stop 137
18.8 NC rotary table 138
18.9 Legend for circuit diagrams 139
19. Coolant system (optional) 140
19.1 Setting up the coolant system 140
19.2 Mounting of the coolant system to the
tool machine cabinet (optional) 140
19.3 Mounting of the coolant return tray (optional) 141
19.4 Safety regulations for the handling of cooling lubricant 142
19.5 Filling the coolant system 142
19.6 Operating the coolant system without CNC control 143
19.7 Operating the coolant system with CNC control 143
19.8 Positioning the segmented coolant hose 144
19.9 Controlling the flow of coolant using the coolant shut-off valve 144
19.10 Drawing and legend 145

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Contents
20. Safety cabin (optional) 146
20.1 Setting up the safety cabin 146
20.2 Mounting of the safety cabin to the
tool machine cabinet (optional) 146
20.3 Safety regulations for the handling of cooling lubricant 147
20.4 Filling the coolant system integrated in the safety cabin 147
20.5 Operating the coolant system with CNC control 147
20.6 Positioning the segmented coolant hose 147
20.7 Controlling the flow of coolant using the coolant shut-off valve 147
20.8 Drawing and legend 148
21. Holding bracket (optional) 149
21.1 Mounting the holding bracket to the milling machine 149
21.2 Inserting the drive into the holding bracket 150
21.3 Drawing and legend 150
22. NC rotary table (optional) 151
22.1 Clamping of work pieces on the NC rotary table 151
22.2 Swivelling the worm shaft in and out 151
22.3 Setting the axial play oft he NC rotary table 152
22.4 Removing the NC drive unit 153
22.5 Setting the axial play of the worm shaft 154
22.6 Setting the axial play of the eccentric tappet 154
22.7 Drawing and legend 155

8
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: [phone] Fax: [phone]
D-54673 Neuerburg WABECO Str. 1-10 Telephone: [phone] Fax: [phone]
that the following named
Universal boring and milling machine
Type:
F1200 - F1200 hs
F1210 - F1210 hs
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 13128:2009
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
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: [phone] Fax: [phone]
D-54673 Neuerburg WABECO Str. 1-10 Telephone: [phone] Fax: [phone]
that the following named
CNC milling machine
Type:
F1200-C - F1200-C hs
F1210-C - F1210-C hs
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 13128:2009
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

10
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: [phone] Fax: [phone]
D-54673 Neuerburg WABECO Str. 1-10 Telephone: [phone] Fax: [phone]
that the following named
CNC milling machine
Type:
CC-F1200 - CC-F1200 hs
CC-F1210 - CC-F1210 hs
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 13128:2009
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