WIVAMAC DB1000 2.1 User manual

Operation manual page 1 / 26
Operation manual
WIVAMAC® Lathes
DB1000 2.1
DB1000 2.2
Willy Vanhoutte BV.
Industriepark Noord 12
B-8730 Beernem
Tel: [phone]
Fax: [phone]
Email: [e-mail]
Web: www.wivamac.com

Operation manual page 2 / 26
CONTENT
CONTENT 2
1 GENERAL 4
1.1 INTRODUCTION 4
1.2 LIABILITY - WARRANTY 4
1.3 BEFORE PUTTING INTO USE 4
1.4 EXPLANATION OF SYMBOLS USED IN THIS MANUAL 5
1.5 PICTOGRAMS 5
1.5.1 Command signs 5
1.5.2 Danger signs 5
2 DECLARATION OF CONFORMITY 6
3 TRANSPORT, STORAGE, MOUNTING AND DISMANTLING OR MOVEMENT OF THE LATHE 7
3.1 CONDITIONS 7
3.2 ASSEMBLY, DISMANTLING OR MOVEMENT 7
3.2.1 Delivery of your lathe 7
3.2.2 Component checklist 7
3.2.3 Assembling the lathe 8
4 SPECIFICATIONS 11
4.1 OBJECTIVE 11
4.2 TECHNICAL SPECIFICATIONS 12
4.2.1 Specifications 12
4.2.2 Tools and accessories 12
4.2.3 Dust extraction 12
4.3 PHYSICAL WORKING ENVIRONMENT. 13
4.4 SET-UP - WORK AREA 13
4.5 INSTALLATION AND PUTTING INTO SERVICE 14
4.6 ELECTRICAL CONNECTION 15
5 OPERATING INSTRUCTIONS 15
5.1 DAILY INSPECTION 15
5.2 EMERGENCY INSTRUCTIONS 16
5.3 OPERATION 16
5.3.1 Operation of lathe with Vario-system 16

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5.3.2 Special precautions for all lathes: 18
5.4 CHANGING THE SPEED – BELT DRIVE 18
6 INSTALLING & REMOVING DRIVE & TAIL CENTRES 18
7 USING THE SPINDLE LOCK 19
8 MOUNTING AND REMOVING CHUCKS & FACEPLATES 20
8.1 USING SPINDLE INDEXING 20
8.2 ROTATING THE HEADSTOCK FOR LARGE-DIAMETER/BOWL TURNING 21
9 SAFETY INSTRUCTIONS 22
10 GENERAL MAINTENANCE INSTRUCTIONS 24
10.1 CLEANING & CORROSION PREVENTION 24
10.2 BEARINGS 24
10.3 REPLACING THE DRIVE BELT 24
10.4 TIGHTENING THE CAMLOCKS ON TAILSTOCK AND BANJO/TOOLPOST 25
10.5 MECHANICAL 26
10.6 ELECTRICAL 26
11 REMOVING AFTER USE. 26
PRODUCT SPECIFICATIONS 26

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1 GENERAL
1.1 Introduction
The lathe has been designed and built in accordance with European guidelines and
according to the European safety and construction standards
The manual contains all information in order to execute a proper set-up of the lathe. The
instructions for using and maintaining the lathe safely are also included.
THE PERSONNEL THAT HAVE TO INSTALL, USE THE LATHE, CHECK OR MAINTAIN THE LATHE,
MUST HAVE READ THIS MANUAL BEFOREHAND.
It is recommended to look after this manual carefully. However it should be within the reach
of whoever needs to consult it at all times. The manual forms an integral part of the machine.
The lathe or machine may only be used for the purpose for which it was designed.
THE MANUFACTURER DECLINES ALL RESPONSIBILITY IF THIS MANUAL HAS NOT BEEN READ OR
THE INSTRUCTIONS THEREIN HAVE NOT BEEN APPLIED.
1.2 Liability - Warranty
The WIVAMAC® lathes are guaranteed for a period of 5 years on the mechanical parts and 3
years on the electrical equipment.
The warranty only covers material or workmanship. Parts subject to wear, such as: drive belt,
bearings, motor, etc, are not covered by this warranty.
No warranty claims can be made for damage caused by improper treatment or use and non-
compliance with these instructions. Damage caused by failure of the electrical installation,
overvoltage or current surges on the electrical grid and the non-observance of the electrical
requirements is not covered by this warranty.
The manufacturer assumes no responsibility for any damage incurred through improper use
or not following the instructions.
The warranty is voided upon changes to the machine or parts thereof, inadequate
maintenance, parts replacement by non-original parts.
1.3 Before putting into use
Prior to the machine being delivered, it is subjected to a thorough test. This test is monitored
by our production manager.
Prior to taking on the machine, the customer may optionally request a verification of correct
installation at its own charge.
He may also call upon us for information and training related to the use and maintenance of
the machine.

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1.4 Explanation of symbols used in this manual
TIP: SUGGESTION OR RECOMMENDATION TO PERFORM TASKS
TAKE NOTE: COMMENTS WITH REFERENCE TO POTENTIAL PROBLEMS
CAUTION: INDICATES DAMAGE TO THE PRODUCT IF NOT WORKED CAREFULLY
WARNING: INDICATES DAMAGE TO THE USER OR THE PRODUCT IF THE
PROCEDURES ARE NOT CAREFULLY FOLLOWED
MORTAL DANGER: CAN IMMEDIATELY THREATEN THE LIFE OF THE USER
1.5 Pictograms
1.5.1 Command signs
read the safety instructions
use of safety goggles
use of respiratory protection
the wearing of safety footwear
1.5.2 Danger signs
dangerous electrical voltage
i
!

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2 DECLARATION OF CONFORMITY
(in accordance with directive 2006/42/EC) (Annex II-1.a)
THE MANUFACTURER: Willy Vanhoutte BV
Industriepark Noord 12
B-8730 Beernem
Belgium
Declares that the machine as described here below:
Lathe
Number: ……………………
Model: DB1000 2.1 - DB1000 2.2
Power:  750W/1HP  1.500W/2HP
Comments/options: ………………………………………………………………………………
Year of manufacture: .............
HAS BEEN MANFACTURED IN ACCORDANCE WITH THE FOLLOWING EUROPEAN
GUIDELINES:
2006/42/EG – Machine safety
2006/95/EC – Low voltage directive
2004/108/EG – EMC Directive
HAS BEEN MANFACTURED IN ACCORDANCE WITH THE FOLLOWING HARMONISED
STANDARDS:
EN 12100
EN 60.204 –1
HAS BEEN MANFACTURED IN ACCORDANCE WITH THE FOLLOWING NATIONAL STANDARDS
AND TECHNICAL REGULATIONS:
DRAWN UP IN: BEERNEM
ON: …. / .... / ..……..
BY: FILIP WAUTERS
FUNCTION: MANAGING DIRECTOR

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3 TRANSPORT, STORAGE, MOUNTING AND DISMANTLING
OR MOVEMENT OF THE LATHE
3.1 Conditions
During the transport and storage of the machine, it should be protected against all weather
conditions (such as rain, bright sunlight, humidity).
The temperatures should remain between −15 °C and +50 °C and may reach a maximum of
+70 °C for short periods of no more than 24 hours.
Appropriate provisions should be made to prevent damage from moisture, vibrations and
shocks.
3.2 Assembly, dismantling or movement
3.2.1 Delivery of your lathe
Your lathe will normally be delivered only partially assembled in order to minimise
transportation costs and to better protect it from damage in transit.
Before commencing any assembly or unpacking you should check that the lathe does not
appear to be damaged, the packaging is not unduly damage and that there are no places
from which it appears items may have been lost. If you do find damage of this nature then
advise the shipping company as soon as possible after receipt, certainly within two days.
3.2.2 Component checklist
Different models of lathe will be slightly differently configured and packed but the
following should be identifiable:
 Lathe bed,
 “A” frame stand
 Headstock sub-assembly and electrical equipment, built-in for DB1000 2.1 and in a
separate electrical cabinet and control box for DB1000 2.2
 Tailstock
 Banjo and Toolrest
In addition to the readily-identifiable principal components of the lathe, the following items will
normally be shipped in a separate accessories carton(s) unless already installed.
DB
1000 2.1
DB
1000 2.2
 Knockout bar
 2 x Spindle lock pin
 Drive centre Z4
 Revolving centre
 Spanner, 24mm x 19mm
 Key for door/cabinet lock
 Studding M16 x 200 mm
 Nut M16
 Anchor plate 120 x 50 x 15 mm
 Instructions manual with CE-
Certificate
 Knockout bar
 2 x Spindle lock pin
 Drive centre Z4
 Revolving centre
 Spanner 24 mm x 19 mm
 Key for door/cabinet lock
 Bolt M16 x 50mm
 T-form plate M16
 Instructions manual with CE-
Certificate
Any shortages should be notified to the supplier within two days of receipt.

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3.2.3 Assembling the lathe
BED, SUPPORT, AND ADJUSTABLE FEET
Fasten the adjustable feet (E) to the support according to photos
below. The M10 self locking nuts (C) are located on the inside, the
M10 x 30 bolts (A) and M10 washer (D) on the outside. The M10 x 70
adjustment bolt (B) is also located on the inside.
Assemble the bed to the A-frame stand (or foot plates for the
DB801/802/800) with the M10 x 30 (2 x 4pcs). The self-locking or blind
nuts (F) are situated inside the bed.
Before mounting the other components onto the lathe, it is appropriate
to place the lathe in its final position. Ensure that there is sufficient
space left behind the lathe so that the headstock can be completely
turned on the bed. Also ensure that there is enough space to the right
of the lathe in order to be able to slide the tailstock of the bed.
Slightly loosen the 4 bolts (A) at the rear and front side
of each stand. You can now position the bed perfectly
horizontally by means of the setscrew (B) and adapt
the height if necessary. There is an adjustable range
from 50mm. Tighten the bolts (A) firmly.

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HEADSTOCK
The headstock should now be mounted on the assembled bed, proceeding as described
below.
Firstly, identify the centring boss which projects from the underside of the headstock
assembly (B). This serves as the pivot, around which the headstock rotates for turning “off
the bed” and also locates the headstock centrally between the bedways when using the
headstock in an alternative position along the lathe bed. When lifting the headstock onto the
lathe bed, this boss must be positioned in the gap between the bedways so that the
headstock assembly sits on its bottom face. Lift the assembly and place it carefully on the
left hand end of the bed, over the A-frame stand but with all of the bottom face of the
headstock enclosure firmly resting on the bed and with the motor in line with the bed. In this
position, the headstock should be reasonably stable but it will topple easily if pushed: do not
rotate the headstock at this stage as the assembly is not stable in the rotated position without
its mounting bolts in place. Watch out not to squeeze your fingers between the motor and
bed.
For DB1000 2.2:
Open the access door in the headstock and
locate the bolt M16x 1.5 x50 (A). Put this bolt
into the hole of the centre boss (B). Locate the
T-shaped plate 70 x 56 mm (C) and place this
plate on the underside of the headstock,
between the bedways. Screw the bolt (A) into
the plate (C). Screw the bolt fully home, but do
not use any implements to tighten it in place.
For DB1000 2.1:
Completely open the access door and locate
the section of M16 studding (H), approximately
200 mm in length. Working from underneath
the bed, screw the studding into the centring
boss (A) on the underside of the headstock.
Screw the study fully home. Locate the bottom
anchor plate (D), a steel plate approximately
120x50x15 mm thick. Place this over the
studding (H) and secure it using the M16 nut
(G). When finally positioned, the anchor plate
should lie square across the bed, fully
supported on the underside of the bed at both
ends, as indicated in the accompanying
photograph.

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FREQUENCY INVERTER (DB1000 2.2)
The Vario system is normally contained within a separate dustproof
enclosure which protects the equipment. The Vario enclosure must never
be opened whilst the system is connected to the power supply. It is bolted
to the inside of the left stand (see photograph). The necessary holes are
already in the Vario enclosure and stand. Open the enclosure with the
black plastic key which is fixed to the switch of the enclosure. Remove the
2 nuts at the outside of the enclosure. Whilst holding the enclosure in
place, place the 2 bolts from the inside of the enclosure through the holes in
the stand. Fix the enclosure with the 2 nuts. Connect the cable from the
motor to the frequency converter via the blue plug. Connect the speed
sensor cable to the frequency controller.
For the DB1000 2.1 models the frequency converter is built into the
headstock.
TOOLREST SADDLE (BANJO)& TOOLREST
To fit the saddle (A) to the lathe bed is simply a matter of
sliding it on from the tailstock end of the bed. Note that
the anchor plate (B) only slides into the gap between the
bedways one way around. Move the locking handle (G)
left and right until you see the anchor plate at the lowest
position. This will give maximum clearance between the
anchor plate and the bedways. If required the position if
the eccentric clamp system can be adjusted with the M12
self locking nut (C). Once the saddle is fitted, slide it to the
required location, then drop the handle to left or right and
press it lightly to lock the saddle in position. The toolrest
saddle (A) of all machines is equipped with an adjustable
socket (D). This allows for the toolrest (F) to be perfectly positioned (with regard to the
workpiece), even when using the bowl turning attachment. Drop the stem of the toolrest into
the socket after first ensuring that the lockscrew (E) is screwed out sufficiently far to clear the
bore. Tighten the lock screw using the ratchet handle, with the toolrest held at the desired
working height.
TAILSTOCK
The tailstock mounts onto the bed in a similar manner to the toolpost saddle. It also uses a
similar camlock principle to lock the tailstock in place.