Operating instructions Universal Mechanic Lathes
Contents
1. Work spindle Drive CUPU m Infinetely variable spindle speed Spindle e tient toa e sciet ans Cone in spindle nose Cross table Cross table range of displacement Turning carriage s range of displacement Turning carriage s range of displacement Max height of turning tools Guideways Longitudinal support Gross SUDDOED S toes dedo Chips and dirt stripper Tailstock Tail spindle s range of displacement Tail spindle s hole bore esses Lateral displacement of the tailstock aleet m MEINER T c Screw cutting attachment ACV allo snc ONC X rer uns Noise values according DIN 45635 part 1 Emission data No load running Load running 350 mm 100 mm 200 mm 120 mm 1 4 Kw 220V 50Hz 45 2300 20 mm Cone 3 100 mm 50 mm 360 16 mm Dovetail guide and adjustment rails Dovetail guide and adjustment rails Protection of the guides 45 mm Cone 2 10mm 0 085 and 0 16 mm min 0 4 3 0 mm 10 32 thead per inch LpA 63 dB A LpA 67 dB A Subject to technical alterations 2 Drawing and list of parts 2 1 Lubricating plan e 1 M P 1 e S EN AMAA ENE 6 M MAM2. Drawing and list of parts Headstock with gear and tumbler gear 43 44 45 46 ND 10400143 11700053 11810009 11700077 Disc Nut Lubricating nipples Headless pin 42 10 11 10 14 4 15 4 s 46 7 ei d 1 1 d 1 d d A 1 L KZ 1 1 E 1 1 2 1 1 V 1 V 1 i i d 1 1 E d 1 2 d 1 1 Fa i 2 ai PF p j i ef F F d Ki d 5 gt Fr D e a im xu dum am LR Y li i d e p d i X 7 M 7 23 24 25 24 27 28 29 30 31 K Lef lE 6 ut k en wf 2 8 Bed with leading spindle drive and change gear quadrant 2 8 1 Bed with leading spindle drive Part No Pcs Order No Designation 15 NOOR 10 11 12 13 14 17 18 19 PO MO MM oO BR N HS 10400201 10400203 10400204 10400205 10400206 10400207 10400208 10400210 10400211 10400212 11810005 10400214 10400217 10400218 10400219 Toothed racket Bed Supporting bearing front Bushing Leading spindle Supporting bearing rear Thrust block loose Bushing Hexagon socket screw Hexagon socket screw Lubricating nipple Nut Disc Nut Hexagon socket screw 2 8 2 Take up gear cutter Part No Pcs Order No Designation 1 1 10400301 Take up gear cutter 2 1 10400302 Shearing bushing 3 1 1040030
3. Operating instructions Universal Mechanic Lathes CC D4000 E Walter Blombach GmbH Tool and Machine Factory D 42899 Remscheid Am Blaffertsberg 13 Phone 02191 597 0 Fax 02191 597 40 E Mail info wabeco remscheid de D 54673 Neuerburg WABECO Str 1 10 Phone 06564 9697 0 Fax 06564 9697 25 E Mail neuerburg wabeco remscheid de www wabeco remscheid de EC Conformity Declaration 4 1 Technical Data 6 2 Drawing and list of parts 7 2 1 Lubricating plan 7 2 2 Arrangement of take up gears for a 1 mm thread pitch slope 8 2 3 Diagram for reading off speed 9 2 4 Position of tumbler gear when cutting LH thread 10 2 5 Position of take up gears for automatic feed 11 2 6 Operating elements 12 2 7 Headstock with gear and tumbler gear 14 27 1 Headstock 14 27 2 Gear 14 27 3 Tumber gear 14 2 8 Bed with leading spindle drive and take up gear cutter 16 2 8 1 Bed with leading spindle drive 16 2 8 2 gear cutter 16 2 9 CNC control drive Z axis 18 2 10 Tool carriage 20 2 10 1 Saddle apron with cross slide 20 2 10 2 Top slide 21 2 11 control drive X axis 23 2 12 Headstock 25 2 13 Motor frame 2 3 Circuit diagram 29 4 Delivery and installation 30 5 Conditions for best working results 31 6 Starting up and maintenance 31 6 1 Maintenance 31 6 2 Starting up 31 6 3 Lubrication of the machine 32 6 4 Guidelines for the periodical maintenance of the machine 32 T Safety instructions 32 8 Descr
4. Overload coupling In order to avoid damage to the drive system of the leadscrew an overload coupling is fitted on the leadscrew drive side The coupling becomes effective when the machine is overloaded and also when the machine hits an end stop in the longitudinal direction The coupling is pre tensed via the hexagonal nuts 18 and are countered against each other Setting the bearing play on the leadscrew On the RH side the leadscrew is placed radially in bearings in a bronze bushing 10 and axially in two axial bearings 9 8 These two axial bearings allow the leadscrew 6 to be adjusted so that there is no play If you have to adjust the setting of the bearings then first of all the outer of the two capstan nuts 14 must be slackened Then the inner nut is turned against the axial bearing so that the lead screw has no more air axially Then the outer capstan nut is countered against the inner one Description of the modules Tooling carriages 9 4 1 Cross slide The cross slide is situated at the front on a prismaticatic guide and at the back on a flat surface guide The slide is held to the bed from below by means of guide rail 46 At the front on the RH side is the cylindrical screw 39 With the help of this cylindrical screw clamp 76 can be clamped up against the underside of the prismatic guide This clamp is suitable for transverse turning and slicing The dove tailed guide of the cross slide can be adjusted I
5. any changes Move the toothed belt from the drive disc to bolt A and from A to C f g Proceed as described under pos 1 f g 10 Applications 10 2 3 Altering the feeds or thread pitches 3 Changing the feed from 0 085 mm to a metric pitch of 1 5 mm Start the procedure exactly as already described Only toothed belt pulley Z 48 on bolt A has additionally to be substituted by toothed belt pulley Z 34 The feed is switched over via the lever grip on the front side of the cam box When cutting thread please make sure that the feed remains permanently switched on so that the turning chisel gets into the same position every time in the case of several cuttings For this reason when you have finished cutting the chisel is turned out with the cross slide and is brought back by means of a change of direction of the motor via the reversing switch into the origi nal position 10 2 4 LH thread To cut an LH thread all you have to do is bring the RH take up wheel on the tumbler gear and link it into the drive wheel on the main spindle In figure 2 4 you can see the position when cutting an LH thread In order to pivot the tumbler gear all you have to do is loosen the clamping screw 11 Three jaw chuck and four jaw chuck The three jaw chuck serves to clamp circular triangular and hexagonal workpieces centrically to the spindle axis The four jaw chuck serves to clamp square workpieces centrically to the spindle axis 44 Dang
6. in such a way that the lathe centre drill barrel or chuck are automatically ejected when turning back Tool clamping An inner cone CM 2 which is worked into the tailstock sleeve 4 serves to accept the tools By screwing the upper T handle 7 the tailstock sleeve can easily be clamped in any position The tailstock sleeve can be moved axialy over a threaded spindle by using the crank 25 located at the rear end 10 Applications 10 1 Longitudinal and transverse turning Longitudinal turning In the case of longitudinal turning tool moves parallel to the axis of the workpiece For roughing at longitudinal turning the use of either a straight or arcuated turning tool is favourably For smoothing the use of pointed or broad turning tools is favourable Transverse turning The tooling of the face is known as transverse turning In the case of transverse turning the turning tool is moved at 90 degrees to the turning axis of the piece being turned In so doing the compound rest is to be locked The main cutting edge of the turning tool is to be exactly centred so that no scar remains in the middle of the workpiece The arcuated tool is used for transverse turning Siis to 1 2 Roughing tools arcuated to the left and or right By using them a maximum on mate rial is to be cut off in as short a time as possible without paying attention to the finish on the surface of the work piece They can be used for longitudinal an
7. make sure the protective hoods are closed 5 Check the condition of the chuck 6 Starting up and maintenance 6 3 Lubrication of the machine 32 The lathe should be lubricated every 8 operating hours according to the lubricating schedule 2 1 Lubricating points 3 bed guide 4 dove tail guide cross slide 5 dove tail guide top slide and 7 tailstock barrel with the help of an oil can and a standard lubricating oil moving the saddle and the barrel backwards and forwards while doing so All other lubricating points are lubricated at the designated lubricating nipples with a grease gun andstandard roller bearing grease 6 4 Guidelines for the periodical maintenance of the machine Daily The lubricating points in compliance with lubricating schedule 2 1 every 8 operating hours Clean the machine and guides Every 3 months Check the tension of the Poly V and pulley and tighten as every 500 600 necessary operating hours Check the play in the guideways and leadscrews and adjust Check the bearing heat in the main spindle and electric motor 7 Safety instructions 1 The feed line for the motor may only be connected to a shock proof socket or juction box Have the socket or junction box checked by an electrician beforehand protection against chil dren being able to put into operation 2 socket or junction box must be close enough to the equipment that the current carrying cable is subjected to no tensile strain w
8. the motor It is advisable to cut a 4 5 mm wide groove on the thread end in order to be able to disengage the threading tool better In the case of a long thread diameter the lathe centre should travel along with the cutting head in order to avoid the workpiece from being pushed to one side Diagram 1 Setting the thread turning chisel 10 Applications 10 2 2 Application of change gears 41 For the purpose of automatic longitudinal turning there are two feed rates being at your disposal 0 085 mm and 0 16 mm revolution Upon delivery the gears producing a feed of 0 085 mm revolution have been put on Putting on different combinations of gears enables you to cut metric thread ranging from 0 4 to 3 0 mm in pitch The same applies to inch thread ranging from 10 threads to 32 threads in pitch Table on thread cutting mw Table automatic longitudinal feed 0 085 48 14 48 14 48 10 Applications 10 2 3 Altering the feeds or thread pitches 42 When altering the feeds or thread pitches proceed as follows 1 Changing the feed from 0 085 mm to 0 16 mm a Loosen the fixing screw D of the change gear quadrant First loosen the knurled screw at the front of the headstock and open the protective cover b Loosen and remove the hexagonal nuts and washers from the bolts A and B C Loosen the hexagonal bolts A and B Remove the toothed belt connecting A and B Turn bolt B out of the cutter w
9. 10 2 Thread cutting and automatic feed 10 2 1 Thread cutting The thread turning chisel is a form turning chisel with the profile of the thread to be cut It is ground according to jigs diagram 1 and must be adjusted exactly to the middle of the workpiece as oth erwise the profile of the thread would be distorted In order to obtain the correct position of the flanks of the thread to the axis of the workpiece the grinding jig is put against the work piece and the turning tool is adjusted in accordance with it The feed of the thread turning chisel is affected via the leadscrew and must correspond to the thread pitch The gearwheels in the accessories establish the connection between the feed gears and the leadscrew By fitting different conbinations of gearwheels it is possible to cut metric and inch RH and LH threads The different axis distances of the toothed wheels can be adjusted by piv oting the cutting edge and adjusting the cutting screws The feed is switched on by hand on the cam box When cutting thread please make sure that the feed remains continously switched on so that the turning chisel always goes back to the same po sition when carrying cut several cuttings For this reason when the cutting is finished the turning chisel is disengaged from the cross slide because otherwise the flanks and the cuts would be dam aged The chisel is taken back to ist home position via the reversing switch by means of a change of direction of
10. 3 Feather key of shearing bushing 4 3 10400304 Belt pulley Z48 5 1 10400305 Bushing 6 2 10400306 Disc 7 2 10400307 Disc 8 1 10400308 Take up gear bolt 9 2 10400309 Bushing 10 2 10400310 Feather key for bushing 11 2 10400311 Toothed belt 12 2 10400312 Toothed belt pulley Z14 13 1 10400313 Take up gear bolt 14 2 10400314 Disc 15 2 11700053 Nut 16 2 11810009 Lubricating nipple 17 2 11700054 Square nut 2 Drawing and list of parts 2 8 Bed with leading spindle drive and take up gear cutter d 9 10 5 2 11 12 13 2 7 8 6 17 2 Drawing and list of parts 2 9 CNC control drive Z axis Part No Pcs Order No Designation 32 1 Belt pulley Z30 33 1 Threaded pin 34 1 Motor sheet metal 35 2 Earthing screw 37 1 Motor housing 38 1 Step motor 39 4 Washer 40 4 Earthing screw 41 4 Hexagon nut 42 1 Lid for motor housing 43 4 Earthing screw 44 1 Belt pulley Z12 45 1 Zylindrical pin 46 2 Washer for tooth wheel 47 2 Circlip 48 1 Toothed belt 49 1 Protective cover 90 2 Nut 2 Drawing and list of parts 2 9 CNC control drive Z axis 43 42 41 38 47 46 44 45 46 47 37 34 39 40 48 49 2 Drawing and list of parts 2 10 Tool carriage 2 10 1 Saddle apron with cross slide Part No O1 BR D Pcs 1 Order No 10400401 10400402 10400403 10400404 10400405 Designation Lower part of cross slide Nut Disc Hexagon bolt Upper part of cross slide 6 1 10400406 Adjustment rail 7 2 10400407 Felt
11. 400723 10400724 11700013 Designation Master switch Emergency OFF switch Final switch Bottom plate Motor Motor frame Platina holder Earthing screw Base plate Potentiometer complete Nut Guide rail Cylinder bolt Eccentric ring Set collar Protection cab chuck Hexagon socket screw 2 2 13 28 26 29 30 31 32 33 34 Drawing and list of parts Motor frame 20 29 A A RA Fb E A 11700051 10400728 11700026 11700059 10400731 11700026 11700060 11700061 Countersunk heard screw Covering motor frame Hexagon socket screw Hexagon socket screw Protection cab Hexagon socket screw Washer Hexagon socket screw 14 23 3 Circuit diagram 4 30 mains plug emergency OFF main switch reversing switch tu j CT OO ger o E ojo 2 6 10 TT LG d i control electronics 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 drilling and milling machine shows signs of transport damage or if there are grounds for complaint In this case we request your immediate notification Claims made at a later date cannot be acknowledged The lathes must be installed on an appropriate level and firm base This would be for example abase cabinet such as in our accessories programme own work benc
12. 8 2 10400408 Felt 9 2 10400409 Felt clamp 10 2 10400410 Felt clamp 11 14 1040041 1 Hexagonal socket bolt 12 6 10400412 Hexagon bolt 13 1 10400413 Saddle apron 14 2 10400414 Hexagonal socket bolt 15 1 10400415 Cleap holder 16 2 10400416 Clasp nut 17 2 10400417 Pin 18 2 10400417 Guide rail 19 1 10400419 Feather key clasp holder 20 1 10400420 Switch lever 21 1 10400421 Disc 22 1 10400422 Flange 23 1 10400423 Liner 24 2 11810005 Lubricating nipple 25 9 10400425 Hexagonal socket bolt 26 1 10400426 Pinion 27 2 10400427 Scale support 28 4 10400428 Thrust piece scale support 29 4 10400429 Threaded pin 30 1 10400430 Hand wheel 31 2 10400431 Pin 32 2 11810004 Ball 33 2 10400433 Scale ring 34 1 10400434 Flange 35 1 10400435 Liner 36 1 10400436 Take up gear 37 1 10400437 Disc 38 1 10400438 Clamping piece 39 1 10400439 Hexagonal socket bolt 40 1 10400440 Guide piece 41 4 10400441 Hexagonal socket bolt 45 3 11700055 Threaded pin 46 1 10400446 Guide rail 47 1 10400447 Guide rail 48 3 10400448 Threaded pin 2 Drawing and list of parts 2 10 Tool carriage Part No Pcs Order No Designation 52 1 10400452 Washer 53 2 11850002 Feather 54 1 10400454 opindle bearing 55 2 10400455 Deep groove ball bearing 10400456 10400457 opindle square Ball ended crank 2 10 2 Top slide Part No Pcs Order No Designation 1 1 10400501 Top slide lower part 2 1 10400502 Guide ring 3 1 10400503 Pin 4 6 10400504 Hexagonal socket screw 5 1 10400505 Clam
13. MA PN E all 8 working hours all 8 working hours 2 Drawing and list of parts 2 2 Arrangement of take up gears for a 1 mm thread pitch slope LH thread pu N MILL WDD NN 2 Drawing and list of parts Diagram for reading off speed 2 3 OAS EE 1 NNAAN ON PINION JIL CS E CODES N N HUNS SS JL LLL INNS N N L 40 60 80100 160 200 Drawing and list of parts 2 4 Position of tumbler gear when cutting LH thread Tumbler wheel Clamping screw 2 Drawing and list of parts 2 5 Position of take up gears for automatic feed 10 2 2 6 Drawing and list of parts Operating elements Potentiometer turning knob for choosing the speed of the driving electric motor Emergency OFF switch Reversing switch for changing direction of turn main spindle Master switch with undervoltage release Opening and closing of clasp nut Chuck handwheel f r longitudinal support Clamping lever for tool clamping plate Ball ended crank for adjusting of cross slide Chuck for quick adjusting of cross slide Clamping screw for clamping of tool carriage Ball ended crank for adjusting of top slide Chuck handwheel for fastening the centre sleeve of tailstock Clamping lever for fastening the tailstock on guides Ball ended crank for adjusting the centre sleeve
14. The machine must be secured so that it cannot be swichted on by children Make sure that other people do not come in contact with the machine The machine must be kept dry at all times Check the machine frequently for damage Any damage parts must be replaced with original parts and should be fitted by an expert or by us Description of the machine To make sure the machine runs properly and in order to have maximum protection from damage it is necessary for the operator to get to know how the machine works very thoroughly Please read the following instructions very carefully before starting up the machine Labelling On the front of the protective hood you will find tables for the individual feeds and pitches with the combinations of take up gears The take up gears for other feeds and pitches are situated in the accompanying gear set for metric and inch threads In chapter 9 3 we have shown graphically the relationship of the cutting speed of the workpiece di ameter and the machine speed Given a certain workpiece diameter and a certain cutting speed then it is relatively easy to determine the correct speed of the main spindle e g d 30mm v 120 m min you can conclude that 1250 min Description of modules Structural features 9 2 9 2 1 9 9 2 2 e Massive large dimensioned grey cast iron machine bed e Sturdy cross ribbing makes the bed extremely stable and enables you to work with no oscilla tion
15. blic recycling facilties The lathe consists of up to 98 of recyclable materials i e steel cast iron aluminium and 2 of chemical materials e g the coating of electrical leads printed circuits If you have trouble disposing of these parts in a proper manner we would be pleased to help you Upon mutual agreement we will take the complete machine back and dispose of it However the costs for transporting the machine to our plant must be at your expense 48
16. d transverse turning to 3 Offset side turning tool Used for smoothing clean surface in the case of longitudinal and transverse turning to 4 Outside thread turning tool Used for cutting of outside threads to 5 Narrow square nose cutting tool Used for the cutting of grooves and slicing of workpieces When inserting the slicing tool No 5 pay careful attention to the exactness of the centre height of the turning tool Work with low speed and cool the tool use soluble oil or emulsion for cooling serves to lubricate and for the removal of chips The slicing tool is to be clamped as short as possible and at 90 degrees to the workpiece to 6 Right side tool Used for the hollowing out of boreholes Clamp as short as possible in order to avoid ascillations of the turning tool which might otherwise occur uneven surface 10 Applications 10 1 Longitudinal and transverse turning For the reason of the power at the turning chisel take care that the tool is short and fast fixed 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 chisel is placed on the middle of the turning piece The control of the height position of the middle of the workpiece is done with the live lathe center in the tailstock For the regulation of the height position of the turning chisel use with straight sheet steel pieces
17. eet implement the requirements of the above mentioned directives the following appli cable and previously published standards have been adhered to EN 292 1 EN 292 2 EN292 2 Enclosure EN 294 EN 349 EN 418 EN 60204 1 D 54673 Neuerburg City HL Chu Signature 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 After unpacking the machine please check to see if any kind of damage has occurred during trans portation Any complaints must be made immediately Complaints made at a later date cannot be accepted If you have any questions or need any spare parts please quote the machine number lo cated on the front of the motor Wir konnen Ihnen wahlweise unsere Bedienungsanleitungen und Prospekte in englischer und franz sischer Sprache kostenlos zusenden We are able to send you free of charge our Operating Instructions and leaflets in French and or English translation Nous avons la possibilit de vous donner nos Instructions de Service et pros pectus aussi en traduction francaise et ou anglaise sans frais Technical Data Working range Centre distante rs GER Men Centre e EE Largest turning diameter over bed Largest turning diameter over slide
18. er of accident Do not try to clamp larger workpieces The chucking power is then too low and the jaws can detach themselves Mounting of turning jaws The jaws and guides are numbered from 1 3 Open the chuck by means of the chuck key until the jaws loosen order 3 2 1 bzw 4 3 2 1 Now take the inner jaws beginning with the number 1 and put this in the guide number 1 Push the jaw number 1 in the direction of the centre point of the chuck and at the same time turn the chuck key direction tighten When the transverse spiral has taken hold of number 1 number 2 must be put in the guide provided The same now happens to number 2 as to number 1 Proceed with num ber 3 and number 4 in the same way Subsequently examine the position of the jaws Mounting of drilling jaws If afterwards you again want to work with outer jaws the process repeats itself in the same order first jaw 1 then 2 then 3 then 4 12 Tool holder with conical sleeve Only those workpieces may be used which accord to the nominal diameter of the collet chuck Mounting of the tool holder When working with the collet chuck the concentric chuck must be removed from the workspindle In order to do this loosen the three tightening screws by means of the Allan key SW6 included in the accessories Now the chuck can be liftet from the concentric flange of the workspindle and the closer can be inserted into the workspindle by gently pushing it Subsequen
19. f you wish to make an adjustment then first you must loosen hexagonal nuts 12 Tighten threaded pins 45 so that the slide can move backwards and forwards along with ball ended crank 57 After adjusting tighten hexagonal nuts 12 again You can also adjust any axial play which occurs in spindle 38 of the spindle bearing If you wish to make an adjustment first of all you have to loosen threaded pin 29 Now scale support 27 can be turned to the right until there is no more axial play Then tighten threaded pin 29 again After making the adjustment the spindle must still be free to turn easily For calculating the displacement path of the slide on scale support 27 there is a large scale ring 29 divided into millimetres One notch corresponds to 0 05 mm of adjustment and this corre sponds to the same amount of shaving on the workpiece This means that in reality the slide is only adjusted by 0 025mm whereas the diameter of the workpiece changes by 0 05mm 9 4 2 Top slide The top slide is clamped via clamp ring 5 on the cross slide upper part 5 Loosen both screws operational elements Pos 6 and the top slide can be pushed or turned along the cross slide This is suitable for lathing short tapered pieces A scale is engraved on guide ring 2 so that you can read the setting exactly The zero line is on the cross slide upper part The dove tail guides of the top slide can be adjusted as described for the cross slide The pa
20. h as long as it is strong enough to carry the weight of the machine without warp ing see technical data and check with spirit level and has an even surface asteel plate The lathe must be firmly screwed down onto the base To facilitate this there are 9 mm holes in the machine base Good results and a minimum of vibration during operation can only be guaranteed if the above mentioned requirements for secure mounting have been kept to The installation of the machine should take place where there is sufficient lighting electrical cables with earthed sockets and O conductors are installed adequately near to the machine so that the mains connection lead is not subject to any tension whatsoever The mains lead should be such that by means of a multiple socket a coolant or lubrication unit can also be connected 5 Conditions for best working results 3l Fix the machine on a sturdy level support Use sharp processing tools Adjust speed setting and feed to fit the material and diameter of the tool Clamp the tools so that the clamping position is as near possible to the work piece Clamp the workpieces fast and without vibrations Long pces support with tailstock or with fixed stay Apply coolant and lubricant for better surface quality finish and dimensional ac curacy Fix processing tools and workpieces on clean clamping surfaces Grease the machine sufficiently Use the correct tools for removing the material from the wo
21. hatsoever 3 When maintenance or cleaning work is being done the machine must be shutdown and the mains plug pulled out 4 Do not brake workpieces or chuck by hand or any other objects 5 Wear safety goggles when working the machine 6 Do not remove the chips with the hand Use corresponding aids hand brush hook paint brush 7 Always keep the protective hood on the driving mechanism closed 8 The turning tools must be firmly tightened at the correct height and as short as possible 9 The turning tools must never be exchanged when the machine is running 10 Never leave the clamping chuck key in even when not in operation 11 Observe the bearing distance of the turning chuck turning jaws max 40mm 4 drilling jaws max 100mm 12 Never take measurements on workpieces being turned danger of accidents and damage to the measuring gauges 7 Safety instructions 13 Do not wear loose items of clothing ties shirt sleeves jewellery etc 8 8 1 9 9 1 34 14 15 When working between centres always centre well in order to avoid a flying out of the work piece In addition check the tightening screw of the tailstock to make sure it is tight When working with automatic advance take care that the cross table does not touch the chuck or the tailstock Never leave the machine when in operation When turning wood use the lathe centre for the slaving of the work piece instead of the lathe chuck
22. iption of modules Electrical parts All the electrical equipment is housed in the box situated at the rear side of the headstock The AC motor is supplied already installed The shock proof plug can be connected directly via a shock proof socket to the 220 V mains supply All 230V machines are fitted with a master switch with undervoltage release i e this switch must be switched on before the machine can be switched on via the reserving switch The master switch must also be switched on again following a power failure If you wish to change the direction of turn of the motor with a reversing switch then in the case of Electronic Lathe 10600 the reversing switch must remain in the O position for about one second so that the relay on the control platina has enough time to switch over Before connecting the machine to the mains supply you must check the earth 9 2 3 Change of speed The rotational speed of the work spindle can be infiniely varied between 45 and 2 300 rpm using the potentiometer on the front of the machine The drive belt must be relocated if the lower speed stage with a minimum speed of 45 rpm is re quired Please proceed as follows see headstock Remove the protective hood and slacken the drive belts To do this slacken nut and screw Turn back toothed belt pulley 23 so that drive belt can be let down with no problem on to the different wheel transmission 12 and 23 To tighten the belts tighten toothed belt
23. iption of the machine 33 8 1 Labelling 33 9 Description of modules 34 9 1 Structural features 34 9 2 opindle head 34 9 2 1 Main spindle 34 9 2 2 Electrical parts 35 9 2 3 Change of speed 35 9 2 4 Speed transmission from main spindle to leadscrew 35 9 2 5 Tumbler wheel adjustment 36 9 2 6 Protective cover for chuck 36 9 3 Bed with leadscrew drive 36 9 3 1 Overload coupling 36 9 3 2 Setting the bearing play on the leadscrew 36 9 4 Tooling carriages 37 9 4 1 Cross slide 37 9 4 2 slide 37 9 5 Tailstock 38 10 Applications 39 10 1 Longitudinal and transverse turning 39 10 2 Thread cutting and automatic feed 40 10 2 1 Thread cutting 40 10 2 2 Application of change gears 41 10 2 3 Altering the feeds or thread pitches 42 10 2 4 LH thread 43 11 Three jaw chuck and four jaw chuck 44 12 Tool holder with conical sleeve 44 13 Square turret head 45 EC Conformity Declaration In the name of the manufacturer Walter Blombach GmbH Tool and Machine Factory based in Remscheid and Neuerburg D 42871 Remscheid Postfach 12 01 61 Phone 02191 597 0 Fax 02191 597 40 D 54673 Neuerburg WABECO Str 1 10 Phone 06564 9697 0 Fax 06564 9697 25 We hereby declare that the universal lathes specified below Universal mechanic lathe Typ D4000E meet the following regulation requirements for standard serie production EC directive for machines EEC 91 68 and 89 392 EC low voltage directive 72 23 EEC In order to m
24. ith the two tooth pulleys and take them out Remove toothed belt of drive disc to A d Remove both tooth belt pulleys Z 14 from their bolts A and B and change them for tooth belt pulley Z 18 or tooth belt pulley Z 20 respectively e Mount bolt B together with both tooth belt pulleys into the change gear quadrant again by slightly tilting the bolt and screwing it into the square nut located behind the quadrant Put on the toothed belt connecting B and C pull bolt B upwards imparting tension to the toothed belt Then tighten bolt B Put toothed belt of of drive disc on bolt A and from bolt A on bolt B f Pull bolt A upwards until the toothed belt is under tension then tighten bolt A Move quadrant to the front until toothed belt of drive disc is tensed to bolt A Then tighten fixing screw D mount washers and nuts on A and B and tighten g Close the cover of the headstock and tighten again the screw with hexagonal recessed hole 2 Changing the feed from 0 085 mm to metrical thread pitch 1 0 mm a c Proceed exactly as already described under pos 1 a c The procedure differs merely as described under 1b in additionally taking away the hexagonal socket screw off bolt C d Changing bolt and the tooth belt pulley Z 48 running on bolt C First push bolt on bolt C then the tooth belt pulley Z 14 Bolt B with totoothed belt will not be needed with thread cutting e As the toothed belt Z14 is already on bolt A you do not have to make
25. of tailstock d D OR eck sch sch SE I 2 Drawing and list of parts 2 6 Operating elements 2 2 7 2 7 1 Drawing and list of parts Headstock with gear and tumbler gear Headstock 2 1 3 2 2 7 Part No CON OOF 26 2 28 29 30 31 Tumbler gear Part No 32 33 34 35 36 37 38 39 40 41 42 Pcs NO Pcs ech Pcs Order No 10400101 10400104 10400105 10400106 10400107 10400108 10400109 10400110 10400111 10400112 10400113 10400114 11810005 10400116 10400117 10400118 10400119 10400120 10400121 10400122 Order No 10400123 10400124 10400125 10400126 10400127 10400128 10400129 10400130 10400131 Order No 10400132 10400133 10400134 10400135 10400136 10400137 10400138 10400139 10400140 10400141 10400142 Designation Tapered roller bearing Headstock Flange front Work spindle Oil wiper ring Feather key Flange rear Distance ring Belt pulley Belt pulley Adjusting nut Countersunk screw Lubricating nipple Hexagon socket screw Belt short for gear Belt Cover plate Knurled nut Threaded pin Hexagon socket screw Designation Belt pulley Ball bearing Bushing Axis Circlip Disc Handle Disc Nut Designation Belt pulley Ball bearing Bolt Handle Clamping bolt Fixing bolt Bushing Feather key Belt pulley Z52 Belt pulley Z16 Flanged wheel
26. ping piece 6 1 10400506 Nut 7 1 10400507 Top slide upper part 8 1 10400508 Adjustment rail 9 1 10400509 Thread bolt 10 3 11700056 Threaded pin 11 3 1040051 1 Nut 12 1 10400512 Pin 13 1 10400513 Clamping claw 14 1 10400514 Thrust disc clamping claw 15 1 10400515 High nut 16 1 10400516 Hexagonal socket screw 17 1 10400517 Disc 18 1 10400518 Hexagonal nut 19 1 10400519 Saddle 20 2 10400520 Deep groove ball bearing 21 1 10400521 Spindle 22 1 11810004 Ball 23 1 10400523 Pin 24 1 10400524 Ball ended crank 25 3 10400525 Thrust piece scale support 26 3 10400526 Threaded pin 27 1 10400527 Scale support 28 1 10400528 Scale ring 29 1 11850002 Feather 30 1 10400530 Feather 2 Drawing and list of parts 2 10 47 Tool carriage Cross slide 55 32 53 33 2 29 e 10 TE 46 41 48 12 11 9 7 38 A 3 41 40 33 2 Drawing and list of parts 2 10 Tool carriage Saddle apron 18 16 17 15 13 34 35 11 36 22 26 20 21 11 a gt 55 25 55 32 A53 29 28 31 T JU 2 130 1 13 Top slide 14 15 20 4 19 20 28 22 29 21 27 TE 10 23 9 i 9 2 24 25 26 4 18 17 6 8 2 Drawing and list of parts 2 11 CNC control drive X axis Part No Pcs Order No Designation 13 1 Feather 14 1 Ball 15 1 Zylindrical pin 16 1 Ball ended crank 20 1 Scale ring 39 4 Earthing screw 76 1 Belt pulley 77 3 Threaded pin 78 1 Motor mechanism plate 79 1 Clamping plate 80 4 Auxilia
27. pulley 53 until the belts on the discs do not slip Tighten nut 26 again 9 2 4 Speed transmission from main spindle to leadscrew The gearwheel 11 on the main spindle drives the take up gearwheels 32 on the tumbler gear On the centre of rotation of the tumbler gear there is a gearwheel 40 with a toothed belt wheel 41 The gearwheel is driven by the take up gears and the toothed belt wheel takes over the drive of the gear combination on the change over cutter 9 Description of modules 9 2 5 Tumbler wheel adjustment 36 9 2 6 9 3 9 3 1 9 3 2 9 9 4 As shown in the diagram 2 2 the right hand wheel on the tumbler gear is engaged in the gear wheel of the main spindle This setting is for LH threads i e if the spindle is turning in an anti clockwise direction looking at the chuck then the tooling carriage will move away from the chuck If clamping bolt 36 is slackened then the tumbler gear can be pivoted over to the right so that the left hand take up gearwheel engages the gearwheel of the main spindle With this setting you can then do right hand threads or the slide can run as before given the same direction of turn of the main spindle towards the chuck Protective cover for chuck The main spindle of the machine will only run when the chuck protective hood 24 is closed For safety reasons it is not possible to switch on the machine with the protective hood open Bed with leadscrew drive
28. rkpieces Set correct bearing clearances and align guides early enough 6 Starting up and maintenance 6 1 Maintenance The longtime serviceability is vitally dependent upon a corresponding serving attendance The lathe needs to be cleaned after every turning job In case the lathe is being erected within a moist cellar all naked parts need to be oiled after completed usage to avoid corrision An overall and constant lubrication of all moving parts is highly signeficant In case backlash within the bearings or within the guideways of the slides should occur readjust in time to avoid the bearing or the guideways of the slides being destoyed 6 2 Starting up Before starting up the machine please clean it thoroughly and lubricate all lubricating points with grease Oil the cross support leadscrews guiding rods and tailstock barrel well Check all spindles manually to make sure they move smoothly Run the lathe on the lowest speed Do not run the machine on full load at first Please pay particular attention before you start up the machine 1 Check to make sure the machine is free from protective agent preservative and that all slid ing areas are clean and oiled We recommend the use of petroleum or similar to remove the protective agent 2 Lubricate the machine according to the lubricating instructions 3 Release the clamp from the longitudinal saddle and check the slide displacement manually for both axes 4 Check to
29. rts have a different numbering in the drawing hexagonal nut 11 threaded pins 10 ball ended crank 24 Likewise as described in the case of the cross slide the axial play of the spindle can be adjusted Here the parts are numbered differently spindle 21 spindle bearings 19 threaded pin 26 scale support 27 9 Description of modules 9 4 2 Top slide 38 9 5 As described in the case of the cross slide the top slide has also got a read off scale for its travel path Here one notch corresponds to 0 05mm of movement Since you do not work with diameters on the top slide then this 0 05 mm corresponds to the actual path A complete turning of the crank corresponds to a path of 1mm Tailstock The tailstock can be pushed along the lathe bed and can be lightly clamped in all positions by tight ening hexagonal nut 13 The tailstock consists of an upper and lower part The upper part can be displaced slightly for turning long slim tapered parts maximum 10mm To do this please proceed as follows Loosen hexagonal nut 13 and with the help of the two threaded pins 9 push the upper part in the desired direction The central position of the tailstock is shown by the notch embossed on the side Find out by doing some trial turns if the workpiece is cylindrical and if necessary correct the tailstock setting Solid tailstock sleeve The solid tailstock sleeve which is provided with a millimetre scale 5 is designed
30. ry motor 81 1 Step motor 82 4 Saucer head screw a3 4 Washer 84 1 Belt pulley 85 2 Flanged wheel 86 1 Threaded pin 87 4 Hexagon nut 88 1 Toothed belt 89 1 Protection cab 90 2 Earthing screw 2 Drawing and list of parts 2 11 CNC control drive X axis 2 Drawing and list of parts 2 12 Part No Om P WD Tailstock Pcs sch zk 10400601 10400602 10400603 10400604 10400605 10400606 10400607 10400608 10400609 10400610 10400611 10400612 10400613 10400614 Designation Tailstock Upper part of shim Lower part of shim Quill ocale Threaded pin Ball ended crank Lower part of tailstock Threaded pin Shim Hexagon bolt Washer Hexagon nut Scale short 15 1 10400615 Spindle 16 1 10400616 Flange 17 1 11810005 Lubricating nipple 18 2 10400618 Hexagon socket screw 19 1 11850002 Feather 20 1 11810004 Ball 21 1 10400621 Threaded pin 22 1 10400622 Pressure sping 23 1 10400623 Scale support 24 1 10400624 Scale ring 25 1 10400625 Ball ended crank 26 1 10400626 Pin 2 Drawing and list of parts 2 12 Tailstock 23 2 Drawing and list of parts 2 13 Motor frame Part No CONOR WD O OQ 20 O n sch a A Nal Order No 11800001 11800008 11800014 11800005 10400705 10400706 10400707 11700057 10400709 11800004 11700002 10400720 11700057 10400722 10
31. s e he wide prismaticatic guide is ground e Cross and longitudinal support with dove tail guides and adjusting rails e A stripper for chips and dirt on all guides e Large dimensioned pivoting scale rings 0 05 mm exactness e Main spindle sited in adjustable tapered roller bearings e Ground main spindle nose e Electronic infinitely adjustable spindle speeds e Manageable ergonomically arranged controls e Equipped with Emergency Off tracer e Main switch with undervoltage release e Motor switchable left right e Tailstock with its own prismaticatic guides e Large torque on main spindle via gear reducing units Spindle head Main spindle The spindle head is firmly attached to the slide bars In the spindle head the work spindle is run on two adjustable precision tapered roller bearings Should a readjustment of the bearings be neccessary please proceed in the following man ner 1 Loosen the locking screw in the adjustment nut The adjustment nut is located at the rear end of the work spindle 2 Turn the adjustment nut in a clockwise direction until the bearings again run free of play the work spindle being easily able to be turned by hand 3 Tighten the locking screw again Roller bearing adjusted too tightly become useless after a short period The spindle throat capacity is 20 mm For safety reasons the whole drive is completely covered with a protective hood and is fixed on to the headstock Descr
32. sould be cleaned with acidic syndets without abrasive ingredients and rich cream should be ap plied to regenrate the skin Please also take note of the enclosed information on the general operating instructions 47 15 Declaration of noise levels in accordance with DIN EN 24871 German Industrial Standard Noise levels while running idle Acoustic capacity level 67 dB A Sound pressure level on operator s ear 63 dB A The stated values reflect emission levels and not necessarily working levels Although there is a corre lation between the level of emission and the level of stress this cannot be used reliably in order to de termine whether additional safety measures are necessary or not Other factors which influence the actual stress level or employees are the characteristics of the work ing area other sources of noise i e the number of machines and other processes going on nearby and so on Apart from that the permitted stress levels may vary from country to country This informa tion is to allow the user of the machine to assess the dangers and risks more accurately 16 Disposal of the lathe The transport and protective packaging made up of the following materials corrugated cardboard polystyrene free of freon polyethelene foil non returnable wooded pallet untreated Euro pallet deposit If you have no further need of these articles or do not wish to use them again please dispose of them at the pu
33. tly insert the required collet chuck into the closer and by means of the hand draw in tube which is fed in through the hollow workspindle from the gear side draw the collet chuck into the closer 13 Square turret head 45 The square turret head is used instead of the clamping plate in order to clamp the tools Four turning tools can be changed simultaneously By swivelling the turret head by 90 degrees each time the required turning tool can quickly be brought into its working position Advantage Paring chisels are always in the centre after being adjusted just once 14 Unit for lubrication coolant 46 The unit for lubrication coolant consists of 1 Tray with lubrication coolant sump which collects the lubrication coolant mixture for the feed pump Contents generally 19 litres 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 lead with a length of 2 m complete with earthed plug Adjustable felxible pressure tubing with stop valve and nozzle for transporting the lubrication cool ant to the processing point An increasing number of customers wish to include this fixture in their order so as to take advan tage of wet processing for the production of their goods workpieces and to to cool and lubricate in particular during lengthy processing when processing high alloy stell an al
34. uminium to increase the tool life to inporove the surface finish and accuracy of the workpieces to reduce friction heat to prevent built up edges When using lubrication coolants especially water based emulsios a number of health and safety measures must be observed which we would like to recommend as follows 1 2 9 4 Use concentrated products free of nitrates Use concentrates without secondary amins Use products with the lowest possible allergy potential When mixing a refill of lubrication coolant please observe the following clean rinse the circulation system tray filter determine the concentration necessary to meet the technical demands concentrate water 1 5 1 30 check the water has a low level of nitrates 50 mg NO 3 test strip A cleaning plan should determine at what intervals the system should be cleaned of swarf and other waste A service plan should determine the following when to check the concentration in use daily weekly when to check the pH values weekly when to check assess the bacteria count monthly when to check the nitrate content weekly The information in brackets can be varied according to the production circumstances In order to reduce splashing we recommend the attachment of a splash guard and or reducing the amount sprayed from the nozzle Since steps to protect the skin must be taken it is advisable to wear gloves and aprons The skin
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