Please read before start-up! Operating instructions Universal Lathes Version of 09/2009 D2000 D2400 D3000 Walter Blombach GmbH Tool and Machine Factory D-42899 Remscheid Am Blaffertsberg 13 Phone: 0049 (2191) 597-0 Fax: 0049 (2191) 597-40 D-54673 Neuerburg WABECO Str. 1-10 Phone: 0049 (6564) 9697-0 Fax: 0049 (6564) 9697-25 www.wabeco-remscheid.de E-Mail: info@wabeco-remscheid.de E-Mail: neuerburg@wabeco-remscheid.
Dear customer! Congratulations on choosing the WABECO Universal Lathe. We have taken great care in its manufacture and we have given it a thorough quality control test. These operating instructions are to help you to work with it safely and properly. Therefore, please read the respective instructions carefully and pay attention to them. After unpacking the machine please check to see if any kind of damage has occurred during transportation. Any complaints must be made immediately.
Index 1. 1.1 1.2 1.3 EC Conformity declaration Machine dimensions D2000 D2400 D3000 4 5 5 5 6 2. Delivery and installation 7 3. Conditions for best results 7 4. Overload protection 8 5. Safety instructions 8 6. 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 Start-up and maintenace Electronical equipment Start-up Maintenance Lubrication Initial cleaning of the machine Headstock Cross support Tailstock 9 9 9 9 10 10 11 11 12 7. 7.1 7.1.1 7.1.2 7.1.3 7.
EC – Conformity Declaration Version 07.2010 In the name of the manufacturer Walter Blombach GmbH Tool and Machine Factory based in Remscheid and Neuerburg D-42871 Remscheid D-54673 Neuerburg Postfach 12 01 61 WABECO Str.
1. Machine dimensions 1.1 D2000 1.
1. Machine dimensions 1.
2. Delivery and installation The lathes are carefully packed in our factory. Please check the following on delivery: 1. whether the packaging has been damaged and/or: 2. whether the lathe shows signs of damage in transit or if there is any other reason for complaint. In this case we request your immediate notification. Claims made at a later date cannot be accepted. The lathe must be installed on appropriate, plain and firm ground.
4. Overload protection i 5. Wait approx. 1 second after switching off the machine manually or after an automatic switchdown following an overload before switching it on again. This will ensure that the motor is protected effectively in all work situations. Otherwise the machine may not run up again because the electronics relay could did not have enough time to react. Safety Instructions 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
6. Start-up and Maintenance 6.1 Electronical equipment The lathes are fitted with a main switch with undervoltage release, i.e. this switch must be turned on before turning on the reserving switch. The main switch must also be switched on again following a power failure. i All lathes can only be switched on with closed plexiglass bonnet. When changing the sense of rotation by turning the right-left switch, the switch must remain for 1 sec.
6. Start-up and Maintenance 6.4 Lubrication Prior to every putting into operation all lubricating points of the lathe must be lubricated with grease for roller bearings of commercial quality. Both guiding bars have to be greased before every putting into operation. The two dovetail guides of the cross support, the threaded spindles accessible from below, the feed shaft as well as the tailstock sleeve have to be greased with lubricating oil every 100 service hours.
6. Start-up and Maintenance 6.6 Headstock The headstock is firmly attached to the guide bars. Inside the headstock, the work spindle is run on two adjustable precision tapered roller bearings. adjustment nut ON -OFF lever for automatic feed If the bearings need to be readjusted, please proceed in the following manner: 1. Loosen the stud bolt in the adjustment nut. The adjustment nut is located at the rear end of the work spindle. 2.
6. Startup and Maintenance 6.7 Cross support If adjustment becomes necessary, please proceed in the following manner: 1. Loosen the lock nuts. 2. Tighten the readjustment screws by using a socket head wrench until the slides can easily be moved to and fro by means of the crank. 3. Re-tighten the lock nuts after the adjustment. Longitudinal support: The longitudinal support which is mounted to the transversal support is pivotable by 360°. Thus, it is suitable for the turning of tapers.
7. Speed regulation 7.1 Speed selection The spindle speed is to be selected according to material type and the diameter of the work piece: Small diameter Large diameter ⇒ ⇒ relatively high speed low speed The cutting speed is the result of rotational speed and diameter.
7. Speed regulation 7.1.3 Speed setting for working with Brass, Copper 7.2 workpiece- Ø approx. r.p.m.. cutting speed m/min 10 mm 2300 80 20 mm 1270 80 40 mm 640 80 60 mm 425 80 80 mm 320 80 100 mm 250 80 Speed change Rotational speed range 45 - 2300 min-1: The rotational speed of the work spindle is infinitely variable between 45 and 400 r.p.m. in the 1st step or in the 2nd step between 200-2300 r.p.m using the potentiometer on the front side of the machine.
8. Applications 8.1 Longitudinal and transverse turning Longitudinal turning: In the case of longitudinal turning the tool moves parallel to the axis of the workpiece. For longitudinal rough turning it is recommended to use either a straight or an arcuated turning tool. For finishing it is best to use pointed or wide turning tools. Transverse turning: The maching of the end faces is known as transverse turning.
8. Applications 8.1 Longitudinal and transverse turning i For the reason of the force effect at the turning tool take care that the tool is short and tightly clamped. If the lever arm is to long the turning chisel curves and springs back. The cutting part enters uneven into the workpiece and is producing a waved surface. Take care that the turning tool is directed to the centre of the work piece. The height position in the workpiece centre is regulated via the live lathe centre inside the tailstock.
8. Applications 8.2.1 General note Feed: The feed is switched on by means of the T-handle on the front side of the headstock. i When cutting threads it must be remembered that the feed remains on throughout to ensure that the turning chisel always returns to the same positon when repeating the thread cutting process.
8. Applications 8.2.
8. Applications 8.2.3 Altering the feeds or thread pitches for D2000 and D2400 When altering the feeds or thread pitches, proceed as follows: 1. a. b. c. d. e. f. g. Changing the feed from 0.085 mm to 0.16 mm Loosen fixing screw D of the change gear quadrant. Loosen and remove the hexagon nuts and washers from the bolts A and B. Loosen the hexagon bolts A and B. Remove the toothed belt connecting A and B.
8. Applications 8.2.3 Altering the feeds or thread pitches for D2000 and D2400 2. Changing the feed from 0.085 mm to a metric pitch of 1.5 mm a. - c. Start the procedure exactly as already described under pos. 1, a-c, with the exception that the hexagon nut must be removed from the quadrant bushing C, too, as additional step of the procedure described under pos. 1 b. d. Pull the bushing and the tooth belt pulley Z 48 off the quadrant bushing C.
8. Applications 8.2.4 Altering the feeds or thread pitch for D3000 1. Working with the automatic longitudinal feed a. Turn the gear lever (19) to the symbol longitudinal turning. Slightly turn the lead screw by means of the ball ended crank (31212) until the clutch disc engages. b. Switch-on the direction switch on the right of the substructure. middle position = off left pressed = feed to the spindle right pressed = feed to the tailstock Adjust the feed speed with the potentiometer. c.
9. Pair of toothed wheels for left-hand thread cutting For cutting left-hand threads, toothed belt wheel No. 11214 on bolt A must be replaced by toothed wheel Z 75 and toothed belt wheel No. 1114 on the main spindle must be replaced by toothed belt wheel Z 50. To do this, proceed in the following manner: a. b. c. d. e f. g. h. i. j. k. Pull the mains plug, loosen the hexagon socket screw on the front of the headstock and open the cover. Remove the belt from the main spindle.
10. Angle plate with milling table For drilling and milling The milling function serves for machining flat surfaces and grooves. When milling with the angle plate the feed motion is effected from the workpiece. If the angle plate is mounted correctly to the cross support (see assembly instructions), the work piece can be rigidly and firmly attached to the clamping plate. It should be clean of dirt and chips beforehand in order to guarantee a good rest.
11. Lubrication coolant unit The lubrication coolant unit consists of: 1. Tray with lubrication coolant tank which supplies the feed pump with lubrication coolant. General content of 19 litres. 2. Feed pump with the following electrical data - nominal voltage 230 V - frequency 50 Hz - nominal current input 0.4A - nominal output 0.07 kW - ON-OFF switch and mains supply with a length of 2 m with earthed plug. 3.
12. Declaration of noise levels in accordance with DIN EN 24871 (German Industrial Standard) Noise levels while running idle Acoustic power level Sound pressure level at operator’s ear 67 dB (A) 63 dB (A) The stated values reflect emission levels and not necessarily working levels. Although there is a correlation between the level of emission and the level of stress, this cannot be used reliably in order to determine whether additional safety measures are necessary or not.
13. Drawings and list of parts 13.1 Headstock for D2000, D2400 and D3000 26 Part-No. Order-No.
13. Drawings and list of parts 13.2 Support with motor and protective cover for D2400 and D3000 Part-No. 125 1251 1252 1253 1254 1255 1256 1260 1258 1257 1259 Order-No.
13. Drawings and list of parts 13.
13. Drawings and list of parts 13.3 Lead screw drive for D2400 and D3000 Part-No. 1119 1145 1146 1147 1149 11491 1261 126111 12611 126112 126113 126114 126115 126118 126116 126117 12612 112 11212 11213 11214 1122 1123 1125 1126 1127 1131 11311 11315 114 1141 11411 11215 114114 1142 1143 114816 114818 114820 114822 114824 114828 114832 114834 114836 114840 Order-No.
13. Drawings and list of parts 13.
13. Drawings and list of parts 13.4 Lead screw drive zu D3000 Part-No. Order-No. Designation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 10300001 10300002 10300003 10300004 10300005 10300006 10300007 10300008 10300009 10300010 10300011 10300012 10300013 10300014 10300015 10300016 10300017 10300018 10300019 10300020 10300021 D.C.
13. Drawings and list of parts 13.
13. Drawings and list of parts 13.5 Drive with gear transmission for D2000 Part-No. Order-No. Designation 1152 119 119 11912 116 1161 11471 114114 11823 11914 11911 1173 11811 11712 1171 1128 11722 11721 1181 11824 11822 182 11821 11825 10101152 10100119 10101120 10111912 10100116 10101161 10111471 102114114 10111823 10111914 10111911 10101173 10111811 10111712 10101171 10101128 10111722 10111721 10101181 10111824 10111822 10100182 10111821 10111825 Support with A.C.
13. Drawings and list of parts 13.
13. Drawings and list of parts 13.6 Cross support Part-No. Order No.
13. Drawings and list of parts 13.7 Tailstock 36 Part-No. Order-No.
13 Drawings and list of parts 13.8 Rear bearing with guide rods Part-No. 5 51 52 522 523 31212 4231 524 53 531 4232 4233 533 541 542 543 544 Order-No.
14. Circuit diagram 14.
mains plug motor feed motor transformer control electronics rectifier capacitor reversing switch potentiometer (rear side) for D3000 control electronics reversing switch 14.2 switch for protective cover main switch Circuit diagram potentiometer emergency OFF 14.
