Related Manuals for WABECO D4000
Summary of Contents for WABECO D4000
- Page 1 Operating Instructions Lathes With prismatic cast iron bed D4000 Bitte vor Inbetriebnahme lesen! Bitte vor Inbetriebnahme lesen!
- Page 2 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.
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Page 3: Table Of Contents
Contents Declaration of conformity for D4000 Important safety notes Intended use Improper and incorrect use Modifications to the machine Safety regulations for proper use Safety features Explanations of the symbols Delivery and set up Transporting the machine Putting into operation... - Page 4 Contents Tool skid – Longitudinal skid Tailstock 3 and 4 jaw lathe chuck Operational faults and the elimination of such Operating elements Drawings and legends 18.1 Electronic console 18.2 Protective hood, drive 1.4 kW motor 18.3 Headstock 18.4 Headstock – Transmission 18.5 Headstock –...
- Page 5 Contents 21.7 Controlling the flow of coolant using the coolant shut-off valve 21.8 Drawing and legend Fixed bezel (optional) 22.1 Operating the fixed bezel 22.2 Drawing and legend Tensioning bracket with milling machine table (optional) 23.1 Mounting the tensioning bracket with milling machine table to the lathe 23.2 Operating elements 23.3...
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Page 6: Declaration Of Conformity For D4000
Werkzeug- und Maschinenfabrik mit Sitz in Remscheid und Neuerburg D-42871 Remscheid Postfach 12 01 61 Telefon: (02191) 597-0 Fax: (02191) 597-40 D-54673 Neuerburg WABECO Str. 1-10 Telefon: (06564) 9697-0 Fax: (06564) 9697-25 that the following named Universal lathe Type: D4000... -
Page 7: Important Safety Notes
Important safety notes 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. - Page 8 Important safety notes 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.
- Page 9 Important safety notes 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.
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Page 10: Safety Features
Important safety notes 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. -
Page 11: Delivery And Set Up
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. -
Page 12: Transporting The Machine
Delivery and set up 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. -
Page 13: Putting Into Operation
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 ■... -
Page 14: Technical Data
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... -
Page 15: Dimensions Front View
Specifications regarding the machine Dimensions Front view A 4 fixing holes M8 (20 mm deep) Dimensions Side view A 4 fixing holes M8 (20 mm deep) -
Page 16: Revolution Selection
Specifications regarding the machine 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: Cutting speed (V) x 1000 Revolutions... -
Page 17: Revolution Changer
Specifications regarding the machine 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. -
Page 18: Electrical Equipment
Specifications regarding the machine 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. - Page 19 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) ■...
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Page 20: Thread Cutting And Automatic Feed
Thread cutting and automatic feed 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. -
Page 21: Tumbler Gear Drive
Thread cutting and automatic feed Tumbler gear drive Setting for right thread and longitudinal feed (factory preset) The toothed wheel (4) on the tumbler gear (1) is in contact with the toothed wheel (5) of the main spindle, thus, when the spindles rotate ant-clockwise (seen from the point of view of the lathe chuck), the tool skid moves towards the lathe chuck. -
Page 22: Use Of Change Gears
Thread cutting and automatic feed Use of change gears For automatic longitudinal turning, there are two feeds available with 0.085 and 0.16 mm per revolution (the wheels are set at the factory for feed with 0.085 mm per revolution). Fitting various toothed wheel combinations enables metric thread cutting from 0.10-7 mm and imperial threads with gradients of 10/1"-40/1"... - Page 23 Thread cutting and automatic feed Use of change gears Table for cutting threads with a gradient of less than 0.4 mm. To do this, B1 and B2 are required as in automatic feed. 0.10 0.12 0.22 0.24 0.25 130* 0.75 1.25 1.75 140*...
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Page 24: Maintenance
Thread cutting and automatic feed Use of change gears Z/1“ Maintenance A long lifetime of the machine will depend on the appropriate care and maintenance. ■ All maintenance and repair tasks may only be carried out with the grounded plug pulled. ■... - Page 25 Lubrication of the machine The lathe is to be lubricated every 8 hours of operation in accordance with the lubrication plan. The lubrication points ■ Bed guide ■ Dovetail guide-Transverse skid ■ Dovetail guide-Longitudinal skid ■ Tailstock sleeve Are lubricated with the help of an oil can and an ordinary lubrication oil by moving the skid or sleeve backwards and forwards.
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Page 26: Readjusting The Main Spindle
Readjusting the main spindle The headstock is screwed to the lathe bed. The headstock contains the main spindle with two adjustable precision tapered roller bearings. If adjustment is required, proceed as follows: 1. Open the gear cover hood by undoing the safety screw with the supplied special key 2. -
Page 27: Readjustment Of The Bearing Clearance Of The Lead Screw
Readjustment of the bearing clearance of the lead screw On the right side, the lead screw is axial mounted. This mount enables the lead screw (1) to be set without play. If adjustment to the mount is required, please proceed as follows: Trapezoidal-threaded spindle 1. - Page 28 Tool skid – Transverse skid The dovetail guide of the transverse skid can be adjusted. If adjustment is required, please proceed as follows: 1. Undo the hexagonal nuts (5) 2. Using an Allen key, tighten the threaded pins (7) in such a way that the skid can still be moved easily using the ball crank (1).
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Page 29: Tool Skid - Longitudinal Skid
Tool skid – Longitudinal skid ■ The longitudinal skid is secure to the transverse skid upper section with the clamping ring (3). ■ After undoing the two hexagonal nuts (5) the longitudinal skid can be slid or turned on the transverse skid. -
Page 30: Tailstock
Tailstock ■ The tailstock can be moved on the lathe bed. ■ By moving the clamping lever (3), the tailstock can easily be secured in any position. ■ The tailstock is made up of an upper and lower section. ■ The upper section can be moved by a maximum of ±10 mm in order to turn long, slim tapers. -
Page 31: And 4 Jaw Lathe Chuck
3 and 4 jaw lathe chuck The 3-jaw lathe chuck Is used to tension circular, three and six edged work piece centrally to the spindle axis. The 4-jaw lathe chuck Is used to tension square work pieces centrally to the spindle axis. Risk of accidents ... -
Page 32: Operational Faults And The Elimination Of Such
Operational faults and the elimination of such Operational faults Possible cause Remedy Machine cannot be switched on 230V voltage is not present Plug is not fitted correctly Check the fuse for the socket The chuck protection hood is not Close the chuck protection closed hood Emergency off switch not... - Page 33 Operational faults and the elimination of such Operational faults Possible cause Remedy Transverse or longitudinal skid Guide play is set too narrowly Adapt the guide play cannot be moved or can only Play of the trapezoidal-threaded Adapt the play of the be moved with considerable nut is set too narrowly (only trapezoidal-threaded nut...
- Page 34 Operational faults and the elimination of such Tool cannot be removed from Tailstock sleeve is not fully Fully crank back the tailstock the tailstock sleeve cranked back sleeve to automatically eject tools with ejector lugs Use tool without ejector lugs Place a soft and sufficient wide inlay between the tool and tailstock front.
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Page 35: Operating Elements
Operating elements Potentiometer rotating knob for speed selection of the electrical drive motor Emergency off switch Turn switch for forwards-reverse - main spindle ON/OFF switch with low voltage trigger Switch lever for opening and closing the clasp nut Holding screw for longitudinal skid Tensioning nut for tool clamping plate Ball crank for adjusting the transverse skid Hand wheel for quickly adjusting the tool skid... -
Page 36: Drawings And Legends
Drawings and legends 18.1 Electronic console Part No. Items Order No. Description 51500807-0001 Potentiometer with cable and connector 43.1 51500807-00011 Potentiometer, complete 51500608 Turn switch 51500606-0001 On-Off switch 51500624-0001 Emergency off button, complete... - Page 37 Drawings and legends 18.1 Electronic console Part No. Items Order No. Description 51001015-00021 Board holder with guide rails 16196500004008 Screw 51501402 Control board 16179910006020 Screw 51500102-0002 Motor 51004020-0003 Eccentric tappet 16191300005006 Threaded pin 51500619 End switch 51400405-0001 Cover plate 16191200004010 Screw...
- Page 38 Drawings and legends 18.1 Electronic console Part No. Items Order No. Description 51400403-0001 Chuck protective hood 16191200004010 Screw 47.1 16112500004000 Washer 51004010-0010 Guide rod 51400406-0001 Electronic housing 160705A0010000 Adjusting ring 16191200005020 Screw 16191200006012 Screw 16112500006001 Washer 16191200004016 Screw 51501304 Symbol for earthed connection 16167980004000 Fanned washer 16193400004000...
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Page 39: Protective Hood, Drive 1.4 Kw Motor
Drawings and legends 18.2 Protective hood, drive 1.4 kW motor Part No. Items Order No. Description 51400401-0001 Protective hood, drive 51400404-0001 Protective plate, lead screw drive 51400485-0001 Protective plate, spindle aperture 51508001 Key KW 4 for safety screw 16173800006012 Safety screw 16191200005012 Screw 16112500004000... -
Page 40: Headstock
Drawings and legends 18.3 Headstock Part No. Items Order No. Description 10400104 Headstock 51502517 Lubrication nipple 51502108 Tapered roller bearing 10400105 Flange 10400107 Oil scraper ring 10400106 Main spindle 16191200006012 Screw 16196500006014 Screw 10400109 Flange 10400110 Sleeve 10400111 Toothed wheel 10400112 Gear wheel 10400113... -
Page 41: Headstock - Transmission
Drawings and legends 18.4 Headstock – Transmission Part No. Items Order No. Description 10600117 Gear wheel 51502113 Ball bearing 10600116 Sleeve 10600109 Axes 16047200032000 Securing ring 51004020-0022 Pressure washer 10400129 Transmission lever 10400130 Washer 16193400010000 51006750-0004 Centering ring 51502308 Belt 51502315 Belt 16191200008025... -
Page 42: Headstock - Tumbler Gear
Drawings and legends 18.5 Headstock – Tumbler gear... - Page 43 Drawings and legends 18.5 Headstock – Tumbler gear Part No. Items Order No. Description 51004025-0033 Bolt 51006530-00011 Toothed belt wheel Z16 51007016-0003 Sleeve 51004020-0010 Washer 51502518 Lubrication nipple 16193400008000 1606885A050320 Parallel key 16191300005006 Threaded pin Clamping screw 10600198 Push piece 51007250-0001 Toothed wheel 10400140...
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Page 44: Bed With Lead Screw
Drawings and legends 18.6 Bed with lead screw... - Page 45 Drawings and legends 18.6 Bed with lead screw Part No. Items Order No. Description 10400203 Gear rod 10400201 Screw 16191200005016 Support bearing, right 10400207 Screw 16191200006020 Ball bearing 51502137 Capstan nut 10400214 Lead screw 10400206 Support bearing, left 10400204 Sleeve 10400205 Safety clutch 10400302...
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Page 46: Change Gear Quadrant
Drawings and legends 18.7 Change gear quadrant... - Page 47 Drawings and legends 18.7 Change gear quadrant Part No. Items Order No. Description Toothed belt wheel Z48 51006580-0004 Sleeve 10600214 Parallel key 1606885A050325 Change gear quadrant 10400301 Change gear bolt, long 51004633-0001 16155700008000 Washer 10600222 Toothed belt wheel Z14 51006525-00011 Washer 51004020-0010 Change gear sleeve...
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Page 48: Tool Skid - Transverse Skid
Drawings and legends 18.8 Tool skid – Transverse skid... - Page 49 Drawings and legends 18.8 Tool skid – Transverse skid Part No. Items Order No. Description Transverse skid, lower section 10400401 Transverse skid, upper section 10400405 Washer 10400452 Spindle 51004016-0007 Spindle bearing 10400454 Scale ring 10400433 Steel ball 51502131 Pressure spring 51502009 Dial 51004035-0010...
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Page 50: Tool Skid - Lock Plate
Drawings and legends 18.9 Tool skid – Lock plate... - Page 51 Drawings and legends 18.9 Tool skid – Lock plate Part No. Items Order No. Description 16191200004010 Screw 10400413 Lock plate 51004040-0001 Keylock switch 10400416 Clasp nut 16063250005016 10400417 Guide bar 1606885A040408 Parallel key 51507040-0001 Switch lever 51004015-0006 Washer 51006555-0021 Flange 10400423 Sleeve 51502517...
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Page 52: Tool Skid - Longitudinal Skid
Drawings and legends 18.10 Tool skid – Longitudinal skid... - Page 53 Drawings and legends 18.10 Tool skid – Longitudinal skid Part No. Items Order No. Description Clamping ring 10400505 Guide ring 10400502 Longitudinal skid, lower section 10400501 Longitudinal skid, upper section 10400507 Steel ball 51502131 Pressure spring 51502009 Dial 51004035-0010 Push piece 51007250-0001 Threaded pin 16091300005006...
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Page 54: Tailstock
Drawings and legends 18.11 Tailstock... - Page 55 Drawings and legends 18.11 Tailstock Part No. Items Order No. Description Tailstock upper section 10400601 Tailstock lower section 10400608 Clamping piece 10400610 Sleeve 10400604 Spindle 51004020-0016 Flange 51006550-0003 Screw 16191200006016 Scale ring 10400624 Steel ball 51502131 Pressure spring 51502009 Dial 51004035-0012 Push piece 51007250-0001...
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Page 56: Circuit Diagram
Circuit diagram 19.1 For 1.4 kW motor This document shows all the equipment for the electrical set-up including connection to the power supply network... -
Page 57: Key For Circuit Diagram
Circuit diagram 19.2 Key for circuit diagram Color-code by IEC 60757 Black Pink Brown Blue Violet Green White Grey Yellow Orange Yellow/Green Main spindle motor Power plug Motor plug Clamping bar Motor control board 220 k (ohm) potentiometers spindle speed Emergency switch-off Main switch End switch chuck -cover... -
Page 58: Shavings Tank With Spray Protection Wall (Optional)
20.1 Setting up the shavings tank with spray protection wall When mounting the shavings tank with spray protection wall to a WABECO tool cabinet, the appropriate bores are already present. The tool cabinet ensures a safe base for the lathe or shavings tank with spray protection wall. -
Page 59: Mounting The Shavings Tank With Spray Protection Wall On
Shavings tank with spray protection wall (optional) 20.2 Mounting the shavings tank with spray protection wall on the tool cabinet (optional) ■ The shavings tank with spray protection wall (2) is positioned, as shown, on the tool cabinet (1). ■ The screws and washers required for assembly are included in the scope of delivery. -
Page 60: Drawing And Legend
Shavings tank with spray protection wall (optional) 20.3 Drawing and legend Part No. Items Order No. Description 51400235-0001 Spray protection wall 51400607-0001 Panel 51400484-0001 Shavings tank 16193400008000 16112500008001 Washer 16193300008020 Screw 16193400004000 16112500004000 Washer 16191200004010 Screw... -
Page 61: Coolant System (Optional)
Coolant system (optional) 21.1 Setting up the coolant system When mounting the coolant system to a WABECO tool cabinet, the appropriate bores are already present. The tool cabinet ensures a safe base for the lathe or coolant system. If the coolant system is secured to another suitable surface, the four through holes must be bored into the surface by the client. - Page 62 Coolant system (optional) 21.2 Mounting of the coolant system to the tool cabinet (optional) To screw the lathe to the coolant system proceed as follows: 1. Place the lathe carefully onto the panel (3) and align along the fixing holes. 2.
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Page 63: Safety Regulations For The Handling Of Cooling Lubricant
Coolant system (optional) 21.3 Safety regulations for the handling of cooling lubricant 1. Pay particular attention to leaked coolant as this can quickly cause people to slip and caused accidents as a result. 2. Secure your coolant system in such a way that it cannot be switched on by children. Persons who have not been trained may not operate the coolant system. -
Page 64: Operating The Coolant System
Coolant system (optional) 21.5 Operating the coolant system The switch shown below is located on the mains cable of the coolant pump. Switch position ( 0 ) Pump switched off Switch position ( I ) Pump switched on (Caution: Coolant flow is controlled with the coolant shut-off valve) -
Page 65: Positioning The Segmented Coolant Hose
Coolant system (optional) 21.6 Positioning the segmented coolant hose The flexible segmented hose (shown in blue) is made up of individually adjustable elements and can be shaped by hand or set as required. The segmented hose and the nozzle are to be positioned in such a way that the coolant flows as directly as possible onto the blade of the cutting tool of the lathe. -
Page 66: Drawing And Legend
Coolant system (optional) 21.8 Drawing and legend Part No. Items Order No. Description Coolant system (tank and two shelf inserts) 51401163-0001 Coolant pump 51500119 Screw-fitted hose bush 51504320 PVC fabric hose 51504218 Screw-fitted hose bush 51504318 Bracket 51400400-0001 Collar 51504349 Coolant hose with shut-off valve 51502507 Screw... - Page 67 Coolant system (optional) 21.8 Drawing and legend Panel with screws for securing the lathe to the panel as well as screws for securing the panel to the coolant system and for securing the segmented coolant hose. Part No. Items Order No. Description 51400607-0001 Panel...
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Page 68: Fixed Bezel (Optional)
Fixed bezel (optional) Bezels counteract the bending of longer shafts that is caused by shaving forces. The roll jaws prevent the bending of the turning elements. They are to be set in such a way that the rotating axis of the work piece is precisely flush with the rotating axis of the machine. -
Page 69: Drawing And Legend
Fixed bezel (optional) 22.2 Drawing and legend Part No. Items Order No. Description 51006831-0028 Basic body 16147100008000 Securing ring 51502117 Ball bearing 51401533-0001 Slider with axis 16112500008001 Washer 16193300008020 Screw 16155700008000 16193100008040 Screw 51002051-0002 Clamping bar... -
Page 70: Tensioning Bracket With Milling Machine Table (Optional)
Tensioning bracket with milling machine table (optional) For drilling and milling work ■ For creating even surfaces and grooves ■ The feed and return motions are carried out by the work piece. ■ A machine vice may also be fitted to the milling machine table (6). ■... -
Page 71: Operating Elements
Tensioning bracket with milling machine table (optional) 23.2. Operating elements 1. Crank for adjustment of the milling machine table in the y axis 2. Scale ring for reading off the travel distance of the y axis 3. Lubrication nipple for greasing the spindle bearing 4. -
Page 72: Adjustment Of The Dovetail Guide
Tensioning bracket with milling machine table (optional) 23.4 Adjustment of the dovetail guide 1. Undo the lock nuts (4) 2. Set the adjustment bar using the threaded pins (5) in such a way that the skid is free of play and can be moved with little force. -
Page 73: Drawing And Legend
Tensioning bracket with milling machine table (optional) 23.7 Drawing and legend... - Page 74 Tensioning bracket with milling machine table (optional) 23.7 Drawing and legend Part No. Items Order No. Description 51003790-0001 Milling machine table 51400242-00011 Longitudinal support, under section 51004016-0004 Spindle 51007016-0002 Bronze nut 51001016-0006 Adjustment bar 16143900006000 16091500006016 Threaded pin 51003000-0001 Longitudinal support, upper section 16093800010070 Pin screw 51006831-00332...
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Page 75: Adjustable Longitudinal Stopper (Optional)
Adjustable longitudinal stopper (optional) 24.1 Mounting and operation of the adjustable longitudinal stopper ■ Undo the two screws (7) and remove the clamping piece (6). ■ Place the longitudinal stopper (2) on the front guide prism (2) of the lathe. ■... -
Page 76: Drawing And Legend
Adjustable longitudinal stopper (optional) 24.2 Drawing and legend Part No. Items Order No. Description 51004332-0001 Longitudinal stopper 51002041-0002 Clamping piece 16112500006001 Washer 16193300006016 Screw 16193300006025 Screw 16193400006000... -
Page 77: Collet Chuck (Optional)
Collet chuck (optional) Only use work pieces that correspond to the nominal diameter of the collet. 25.1 Mounting the collect chuck 1. Remove the lathe chuck from the main spindle. To do this, undo the 3 fixing screws using a wrench. -
Page 78: Installation And Removal Of Collets
Collet chuck (optional) 25.3. Installation and removal of collets Installation 1. Place the collet on a flat surface. 2. Place the tensioning nut on the collet 3. Press the tensioning nut down against the collet until it "clicks". 4. The collet can now move freely in the central take-up shoulder and does not fall out when the collet is turned upside down.