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Operating Instructions

1. 76 Items 1 1 3 2 1 1 Order 51004332 0001 51002041 0002 16112500006001 16193300006016 16193300006025 16193400006000 Description Longitudinal stopper Clamping piece Washer Screw Screw Nut WABELU MASCHINENMANUFAKTUR seit 1885 25 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 Remove the lathe chuck from the centring flange of the main spindle Secure the collet chuck in the same way as the lathe chuck Remove the cap nut 1 from the collet chuck 2 Insert the required into the nut see installing and removing collets and screw back onto the collet chuck gt Insert the work piece or tool into the collet 7 Tighten the cap nut with the appropriate wrench 8 Permitted revolution range up to a maximum of 5000 rpm 25 2 Drawing and legend PartNo Items Order No Description 1 1 11727 Cap nut 2 1 51003505 0002 Collet chuck 77 WAHELLU MASCHINENMANUFAKTUR seit 1885 25 Collet chuck optional 25 3 Installation and removal of collets Installation 1 Place the collet on a flat surface Place the tensioning nut on the collet Press the tensioning nut down against the collet until it Clicks BP m The collet can now
2. Tool skid Adjustability of the transverse skid 120 mm Adjustability of the longitudinal skid 50 mm Longitudinal skid can be swivelled by 360 Max turning steel height 16mm Tailstock with quick adjustment Lateral adjustability of the tailstock upper 10mm Tailstock sleeve With inner Morse taper MK2 Sleeve adjustability 45 mm Scale ring read accuracy 0 1 mm Thread cutting Tumbler gear drive For left right thread 2 automatic longitudinal feeds 0 085 und 0 16 mm U Change gear set for thread cutting Metric 0 25 7 0 mm imperial 10 40 G WABELU MASCHINENMANUFAKTUR seit 1885 4 Specifications regarding the machine 4 4 Dimensions Front view 4fixing holes M8 20 mm deep 4 5 Dimensions Side view A 4 fixing holes M8 20 mm deep WAHELLU MASCHINENMANUFAKTUR seit 1885 4 Specifications regarding the machine 4 6 Revolution selection Select the spindle revolutions according to the material type of work piece diameter Small work piece diameter gt 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 Work piece diameter d x 3 14 Application example Thus an aluminium work piece with a of 20 mm is to be turned with a cutting speed of 100 m min 100 x 1 000 100 000 vo
3. We recommend two people to lift the machine using the positions shown 1 To do this a sufficiently dimensioned at least 2 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 Due to the weight of the machine it is advisable to lift the machine by crane if this is possible To lift wrap suitable lashing 2 as shown around the two outer struts of the ribbing of the machine bed When lifting pay attention to an ergonomic stance and sufficient safety In the delivered state the machine feet have two transport straps attached These secure the machine to the transportation pallet They must be removed before setting the machine up WABELU MASCHINENMANUFAKTUR seit 1885 3 Putting into operation Use a dry cloth to remove the corrosion protection that was applied to all exposed parts for transport Inthe 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 set up properly see the section on delivery and set up connect the grounded plug directly to a safety socket and the 230 V 50 60 Hz optional 110 V 60 Hz mains power supply a Provision of sufficient coolant for the operation of a coolant system optional Release the axis clamps and check the individ
4. WABELDU MASCHINENMANUFAKTUR seit 1885 Operating Instructions Lathes With prismatic cast iron bed D4000 WAHELLU MASCHINENMANUFAKTUR seit 1885 Please read before putting into operation for the first time Every person that operates the machine maintains or repairs it must have read the operating instructions and in particular the safety notes prior to putting the machine into operation Please store these documents for subsequent use Original version in German translation in English Status at 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 For this reason we ask you to read the appropriate notes through attentively and to take care to observe them After unpacking the tool check whether any transportation damages have occurred Complaints whatever their nature should be communicated immediately Subsequent claims cannot be recognized For all queries and replacement part orders please always specify the machine number see type plate Reprinting and reproductions of any kind even extracts require the written permission of WABECO Disposing of the machine The transportation and protective packaging is made of the following materials Corrugat
5. Pay attention to the spread of the lathe chuck 28 The maximum revolution range specified on the lathe chuck may not be exceeded 29 The machine only operates when the chuck protection hood is folded over the lathe chuck For safety reasons it is not possible to switch the machine on when the chuck protection hood is up 30 The generated shavings must be caught by the user with the help of a shaving protection device 31 Always keep the gear cover hood closed 32 The gear cover hood may only be opened by a trained person with a special key and when the grounded plug has been pulled out of the socket 33 Turning steels must be firmly tensioned at the correct height and as short as possible 34 Do not measure at the rotating work piece risk of accident measuring tools will be damaged 35 When working between the tips check the locking lever of the tailstock for firm seating 36 Despite the existing safety clutch you should avoid reaching into the rotating hand wheel when the automatic feed is switched on 37 When working with the automatic feed always pay attention to ensure that the tool skid does not come up against the lathe chuck or the tailstock 38 When wood turning use a lathe centre point instead of the lathe chuck to carry the work piece WABELU MASCHINENMANUFAKTUR seit 1885 1 Important safety notes 1 5 Safety features In order to enable you to work safely with our machines we have incorporat
6. protruding threaded bolt Tighten the four nuts using a size 13 combination wrench WABELU MASCHINENMANUFAKTUR seit 1885 21 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 3 Ensure you have a clean workplace dirty areas can quickly lead to accidents 4 Never use the coolant system when processing magnesium alloys In combination with water mixed coolants this may result in flammable gas mixtures which may explode under certain circumstances Avoid longer skin contact with the coolant Use skin protecting creams when handling coolants Regularly monitor the concentration of the water mixed coolant Regularly monitor the pH value of the coolant Se EN Make sure that the coolant is only disposed of in an environmentally friendly way in accordance with the relevant guidelines Coolant is a special waste product 21 4 Filling the coolant system A number of protective measures must be observed and taken in order to ensure that the handling of coolant does not cause health risks or environmental loads Always observe the datasheet and the safety regulations of the coolant being used can be obtained
7. 1592 rpm 20 x 3 14 62 8 Now select from the potential revolutions the one that comes closest to the ideal of 1592 rpm 4 7 Diagram for reading off the revolutions m min 4000 3000 2000 1000 800 600 400 200 120 100 80 60 40 20 10 2 4 6 8 10 20 40 60 80 100 160 200 WABELU MASCHINENMANUFAKTUR seit 1885 4 Specifications regarding the machine 4 8 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 Open the gear cover hood by undoing the safety screw with the supplied special key 2 Undo the hexagonal nut 3 and this loosen the drive belt 1 2 3 Turn the clamping screw 4 anti clockwise in such a way that the drive belt 1 can be placed on the other transmission setting of the belt pulley 5 6 4 Totension the drive belt 1 2 tighten the clamping screw 4 in a clockwise direction in such a way that the drive belt 1 2 cannot slip on the belt pulley 5 Tighten the hexagonal nut 3 back up again 6 Close the drive cover hood again and secure with the safety screw WAHELLU MASCHINENMANUFAKTUR seit 1885 4 Specifications regarding the machine 4 9 Electrical equipment The main drive motor single phase series wo
8. 2 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 Subsequent claims cannot be recognized The machine must be set up on a suitable even and firm surface Suitable surfaces are for example a A tool cabinet available optionally a separate workbench with a level surface spirit level that is strong enough to carry the weight of the lathe without bending a A steel plate with a level surface spirit level The machine must be screwed securely to the surface it is set up on There are holes in the base of the machine that are designed for this purpose Good working results and low vibration operation can only be ensured when the prerequisites for fixture as set out above are maintained The place of set up should be selected in such a way that There is sufficient lighting electrical power supply with safety socket and earth are installed close enough to the machine that the power cable is not subject to any strain power cable should also be dimensioned in such a way that a multiple socket can be used for example to power a coolant system WAHELLU MASCHINENMANUFAKTUR seit 1885 2 Delivery and set up 2 1 Transporting the machine
9. 60 21 Coolant system optional 61 21 1 Setting up the coolant system 61 21 2 Mounting of the coolant system to the 61 tool machine cabinet optional 21 3 Safety regulations for the handling of cooling lubricant 63 21 4 Filling the coolant system 63 21 5 Operating the coolant system 64 21 6 Positioning the segmented coolant hose 65 WABELU MASCHINENMANUFAKTUR seit 1885 Contents 21 7 Controlling the flow of coolant using the coolant shut off valve 65 21 8 Drawing and legend 66 22 Fixed bezel optional 68 22 1 Operating the fixed bezel 68 22 2 Drawing and legend 69 23 Tensioning bracket with milling machine table optional 70 23 1 Mounting the tensioning bracket with milling machine table to the lathe 70 23 2 Operating elements 71 23 3 Feed motion of the milling machine table 71 23 4 Adjustment of the dovetail guide 72 23 5 Alignment of the milling machine table 72 23 6 Lubrication of the tensioning bracket with milling machine table 72 23 7 Drawing and legend 73 24 Adjustable longitudinal stopper optional 75 24 1 Mounting of the adjustable longitudinal stopper 75 24 2 Drawing and legend 76 25 Collet chuck optional 77 25 1 Mounting the collect chuck 77 25 2 Drawing and legend 77 25 3 Installation and removal of collets 78 WABELU MASCHINENMANUFAKTUR seit 1885 Declaration of conformity We hereby declare in the name of the manufacturer Walter Blombach GmbH Werkzeug und Maschinenfabrik mit Sitz in Remscheid un
10. from the supplier or manufacturer Observe all safety regulations set out in these operating instructions in particular those that refer to the safe handling of coolants In order to ensure reliable operation of the coolant pump a minimum coolant filling level is required in the coolant tank capacity of the coolant system is approximately 19 liters The maximum filling level should be just below the shelf insert a The minimum filling level is approximately 15 mm below that To fill remove the shelf insert and fill to the maximum filling level with a suitable coolant whilst observing all safety regulations a After filling replace the shelf insert 63 WAHELLU MASCHINENMANUFAKTUR seit 1885 21 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 gt Pump switched off Switch position 1 gt Pump switched on Caution Coolant flow is controlled with the coolant shut off valve 64 WABELU MASCHINENMANUFAKTUR seit 1885 21 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 Att
11. length of the tool backwards 34 WABELU MASCHINENMANUFAKTUR seit 1885 17 Operating elements 14 24 3 4 17 7 105 11 12 45 B 1 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 oN o m Hand wheel for quickly adjusting the tool skid 10 Clamping screw for clamping the tool skid 11 Ball crank for adjusting the longitudinal skid 12 Clamping lever for securing the tailstock sleeve 13 Lever for securing the tailstock to the guides 14 Ball crank for adjusting the tailstock sleeve 15 Tensioning nut for securing the tailstock to the guides 16 Safety screw for the drive protection hood 17 Chuck protection hood 35 WABELU MASCHINENMANUFAKTUR seit 1885 18 18 1 Part No 43 43 1 44 45 72 36 Drawings and legends Electronic console Items Order No 51500807 0001 51500807 0001 1 51500608 51500606 0001 51500624 0001 Description Potentiometer with cable and connector Potentiometer complete Turn switch On Off switch Emergency off button complete WABELU MASCHINENMANUFAKTUR seit 1885 18 Drawings and legends 18 1 Elect
12. move freely in the central take up shoulder and does not fall out when the collet is turned upside down Removal 1 Hold the tensioning nut in one hand 2 Press up against the collet 3 The lateral pressure on the collet pushes this out of the take up shoulder of the tensioning nut and it can now be removed from the nut 78
13. the thread turning steel gt NS P4 feed of the thread turning steel is carried out via the lead screw and must match the thread gradient a change gears belonging to the accessories create the connection between the feed drives and the lead screw By fitting different toothed wheel combinations it is possible to cut metric and imperial right and left threads The different axis intervals of the toothed wheels be set by swivelling the quadrant and adjusting the quadrant bolt Feed The feed is switched on using the switch lever on the lock plate feed must always be switched on in order for the turning steel to return to the same position when carrying out multiple cutting procedures a After completing the cut bring the turning steel with the transverse skid out of the inroad otherwise the flanks and cutting edges will be damaged Then return the turning steel to the starting position by changing the direction of rotation of the motor via the turn switch for forwards reverse It is good if the thread end has a 4 5 mm wide clearance milled in order to better remove the thread steel out of the way In the event of a long thread diameter the turning center point should always be used to prevent the work piece from pushing away WABELU MASCHINENMANUFAKTUR seit 1885 6 Thread cutting and automatic feed 6 2 Tumbler gear drive Setting for right thread and longitudinal
14. use of the lathes 1 3 Modifications to the machine For reasons of safety it is forbidden for the user to make modifications of any type to the lathe Walter Blombach GimbH accepts no responsibility for property damage and personal injury caused as a result of any modifications to the lathe by the user that have not expressly been authorized by the company 1 4 Safety regulations for proper use The machine may represent a source of danger if it is not used correctly For this reason it is important that the following safety regulations are read attentively and observed carefully Every person that operates the machine maintains or repairs it must have read the operating instructions and in particular the safety notes prior to putting the machine into operation In order to fulfil these requirements these operating instructions must accompany the machine throughout its entire lifetime and be available for research In the event that the machine changes owners the operating instructions must thus be passed on to the new owner along with the machine WAHELLU MASCHINENMANUFAKTUR seit 1885 1 Important safety notes 1 4 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 Weremind you that no liability will be accepted for damages caused by not observing these operating instructions 3 The operat
15. 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 The tool must be clamped as short as possible in the collect risk of breakage The width of the T groove is 12 mm the gap between the two T grooves is 90 mm The prismatic groove in the middle of the milling machine table is used to secure round parts 23 1 Mounting the tensioning bracket with milling machine table to the lathe 70 Remove the longitudinal skid from the transverse skid of the lathe Clean the surface of the transverse skid of dirt and shavings This is the only way to ensure a flat and safe surface Place the tensioning bracket as shown laterally onto the transverse skid In doing so insert the screw head on the underside of the tensioning bracket as shown into the T groove of the transverse skid Slide the tensioning bracket with milling machine table to the required position on the transverse skid and secure the tensioning bracket WABELU 23 Tensioning bracket with milling machine table optional 23 2 Operating elements 1 Crank for adjustment of the milling machine table in the y axis Scale ring for reading off the travel distance of the y axis Lubrication nipple for greasing the spindle bearing Counter nut for securing the threaded pins 5 Threaded pins for setting the guide play Milling machine table for tension
16. 0 120 22 WABELU MASCHINENMANUFAKTUR seit 1885 6 Thread cutting and automatic feed 6 3 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 mm 0 10 0 12 0 22 0 24 0 25 A1 48 48 48 48 48 A2 14 14 24 24 24 B1 14 18 18 18 18 B2 48 48 40 36 48 C 48 48 48 48 36 C1 20 20 14 14 16 140 140 140 140 140 120 120 120 120 130 140 140 140 140 120 mm 04 05 07 0 75 08 1 0 1 25 1 5 1 75 2 0 25 30 35 40 5 0 7 0 A1 48 48 48 48 48 48 48 48 48 48 48 48 24 24 24 24 A2 16 20 14 18 16 14 20 36 28 40 40 48 28 40 40 28 C1 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 32 D 120 120 120 140 140 140 140 120 140 140 120 120 120 140 120 120 F 120 120 120 120 120 120 120 120 120 140 120 140 140 120 140 120 23 472142 MASCHINENMANUFAKTUR seit 1885 6 Thread cutting and automatic feed 6 3 Use of change gears Zh 10 11 12 13 14 16 18 19 20 24 26 28 32 36 40 A1 34 34 34 34 34 34 34 34 34 34 34 34 34 34 34 2 36 36 36 36 36 36 14 34 18 24 18 18 18 14 18 C 20 22 24 26 28 32 14 36 20 32 26 28 32 28 40 C1 16 16 16 16 16
17. 1 WAHELLU MASCHINENMANUFAKTUR seit 1885 18 Drawings and legends 18 5 Headstock Tumbler gear 42 WABELU 18 Drawings and legends 18 5 Headstock Tumbler gear PartNo Items Order 20 1 51004025 0033 22 1 51006530 0001 1 23 1 51007016 0003 24 1 51004020 0010 25 1 51502518 26 1 16193400008000 27 1 1606885A050320 31 2 16191300005006 50 1 10600198 51 2 51007250 0001 92 1 10400140 93 1 10400135 94 2 51502136 95 2 51004015 0004 96 1 10600196 97 1 51008530 0002 MASCHINENMANUFAKTUR seit 1885 Description Bolt Toothed belt wheel Z16 Sleeve Washer Lubrication nipple Nut Parallel key Threaded pin Clamping screw Push piece Toothed wheel Lever Ball bearing Bolt Toothed wheel Toothed wheel plastic 43 WABECO MASCHINENMANUFAKTUR seit 1885 18 Drawings and legends 18 6 Bed with lead screw 44 WABELU MASCHINENMANUFAKTUR seit 1885 18 Drawings and legends 18 6 Bed with lead screw Part No Items Order No Description 1 1 10400203 Bed 2 1 10400201 Gear rod 3 6 16191200005016 Screw 4 1 10400207 Support bearing right 5 4 16191200006020 Screw 6 2 51502137 Ball bearing 7 2 10400214 Capstan nut 8 1 10400206 Lead screw 9 1 10400204 Support bearing left 10 1 10400205 Sleeve 11 1 10400302 Safety clutch 16 1 1606885A050325 Parallel key 17 4 16112500006001 Washer 71 1 10400210 Sleeve 72 2 51502517 Lubrication nipple 45 WAHE
18. 1006731 00021 24 1 51004025 0009 25 1 16073430003024 26 1 51502517 27 2 16091300008010 28 2 51004006 0002 74 Description Milling machine table Longitudinal support under section Spindle Bronze nut Adjustment bar Nut Threaded pin Longitudinal support upper section Pin screw Tensioning bracket Screw Washer Nut Nut Washer Spindle bearing Screw Ball Pressure spring Ball crank Spiral tensioning pin Securing ring Scale ring Adjusting ring Spiral tensioning pin Lubrication nipple Threaded pin Push piece WABELU MASCHINENMANUFAKTUR seit 1885 24 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 a Place the longitudinal stopper 2 on the front guide prism 2 of the lathe a Lightly screw the clamping piece 6 with the screws 7 into place as shown longitudinal stopper can now be pushed to the desired position a Tighten the screws 6 to secure the longitudinal stopper to the machine bed Fine adjustment can be made using the screw 4 that acts as stopper for the transverse skid 3 a Todo this release the counter nut 5 and turn the screw 4 in the desired direction Then tighten the counter nut 5 back up again 75 WAHBHELLU MASCHINENMANUFAKTUR seit 1885 24 Adjustable longitudinal stopper optional 24 2 Drawing and legend Part No
19. 16 16 16 16 16 16 16 16 16 16 D 120 120 120 120 120 120 120 120 120 120 120 120 120 120 120 140 140 140 140 140 140 120 140 120 120 120 120 120 120 120 T 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 The machine must be cleaned after each use If the machine is set up in a wet room all exposed parts must be oiled after each use to prevent corrosion Always lubricate all moving parts well In the event of bearing or skid play immediately adjust in order to prevent it from destroying the bearing or skid guide Approximately every 100 operating hours Clean the carbon brushes and collector of the drive motor 1 4 kW with a piece of coarse sandpaper Remove approximately 0 1 mm from the carbon brushes then smooth out the contact surface with fine sandpaper Check the tension of the poly V and gear belt and adjust if necessary Check the play in the guides and feed spindles and set if necessary 8 Lubrication of the machine The lubrication process Reduces wear and friction Increases the lifetime m Protects metal surfaces from corrosion We recommend class 2NLGI multi purpose grease for lubrication a A lubrication oil with a v
20. 16193400008000 Nut 3 4 16193300008020 Screw 67 WAHELLU MASCHINENMANUFAKTUR seit 1885 22 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 At the support position the turning parts must be accurately rounded 22 1 Operating the fixed bezel 1 The fixed bezel can be secured at any position on the prismatic bed 2 The bezel 1 is fitted to the prismatic guide 3 The clamping plate 2 is inserted from below into the prismatic bed and secured with the clamping screw 3 4 The slider 4 can be moved by opening the clamping screws 5 afterwards the clamping screws 5 must be tightened up again 68 WABELU 22 MASCHINENMANUFAKTUR seit 1885 Fixed bezel optional 22 2 Drawing and legend Part No DO OA FP WD Items WO W BWW OD ex Order No 51006831 0028 16147100008000 51502117 51401533 0001 16112500008001 16193300008020 16155700008000 16193100008040 51002051 0002 Description Basic body Securing ring Ball bearing Slider with axis Washer Screw Nut Screw Clamping bar 69 WAHELLU MASCHINENMANUFAKTUR seit 1885 23 Tensioning bracket with milling machine table optional For drilling and milling
21. 6 Threaded pin 25 1 10400506 Spindle nut 26 1 10400517 Washer 32 1 16073430004014 Spiral tensioning pin 34 3 16091500005020 Threaded pin 35 3 16193400005000 Nut 36 1 10400513 Clamping jaw 37 1 10400514 Pressure washer 38 1 16193400008000 Hexagonal nut 39 1 10400509 Threaded bolt 40 1 16193300008030 Hexagonal screw 41 1 51502010 Pressure spring 42 1 16073430003008 Spiral tensioning pin 44 1 51004016 0008 Spindle 45 1 10400519 Spindle bearing 46 1 10400528 Scale ring 52 1 51507023 0001 Ball crank 53 1 16073430003014 Spiral tensioning pin 54 4 16191200005010 Screw 55 1 16191200005016 Screw 57 1 10400508 Adjustment bar 61 2 10400470 T groove screw 62 2 16143900008000 Nut 69 2 51502116 Ball bearing 85 2 16191200005016 Screw 53 WAHELLU MASCHINENMANUFAKTUR seit 1885 18 Drawings and legends 18 11 Tailstock 7 29 54 WABELU MASCHINENMANUFAKTUR seit 1885 18 Drawings and legends 18 11 Tailstock Part No Items Order No Description 1 1 10400601 Tailstock upper section 2 1 10400608 Tailstock lower section 3 1 10400610 Clamping piece 4 1 10400604 Sleeve 5 1 51004020 0016 Spindle 6 1 51006550 0003 Flange 7 2 16191200006016 Screw 8 1 10400624 Scale ring 9 1 51502131 Steel ball 10 1 51502009 Pressure spring 11 1 51004035 0012 Dial 12 3 51007250 0001 Push piece 13 3 16191300005006 Threaded pin 14 1 16091500006016 Threaded pin 15 1 16193100008060 Screw 16 2 1
22. 6091500006020 Threaded pin 17 1 51004020 0010 Washer 18 1 16193400008000 Nut 19 1 10400605 Scale tape 20 1 51502517 Lubrication nipple 21 1 51507023 0001 Ball crank 22 1 16073430003014 Spiral tensioning pin 23 1 51507033 Tensioning lever 24 1 10400601 Sleeve clamping element top 25 1 10400602 Sleeve clamping element bottom 26 2 16043900008000 Nut 27 1 16191300008040 Threaded pin 28 1 10400636 Clamping bush 29 1 10400614 Scale 30 2 16191200003010 Screw 31 1 10400632 Clamping strap 32 1 51004020 0018 Eccentric shaft 33 1 51004020 0023 Washer 34 1 16073430003018 Spiral tensioning pin 35 1 10400634 Lever 36 1 10600436 Handle 37 1 16193400008000 Nut 55 WABELU MASCHINENMANUFAKTUR seit 1885 19 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 230VAC n 56 WABELU MASCHINENMANUFAKTUR seit 1885 19 Circuit diagram 19 2 Key for circuit diagram Color code by IEC 60757 BK Black PK Pink BN Brown RD Red BU Blue VT Violet GN Green WH White GY Grey YE Yellow OG Orange YG Yellow Green M1 Main spindle motor N1 Power plug N2 Motor plug 4 Clamping bar Pi Motor control board R1 220 k ohm potentiometers spindle speed 51 Emergency switch off S2 Main switch 510 End switch chuck cover 511 Turn swit
23. BELU MASCHINENMANUFAKTUR seit 1885 18 Drawings and legends 18 8 Tool skid Transverse skid 48 WABELU MASCHINENMANUFAKTUR seit 1885 18 Drawings and legends 18 8 Tool skid Transverse skid Part No Items Order No Description 1 1 10400401 Transverse skid lower section 2 1 10400405 Transverse skid upper section 13 1 10400452 Washer 15 1 51004016 0007 Spindle 16 1 10400454 Spindle bearing 17 1 10400433 Scale ring 18 1 51502131 Steel ball 19 1 51502009 Pressure spring 20 1 51004035 0010 Dial 21 3 51007250 0001 Push piece 22 3 16191300005006 Threaded pin 23 1 51507023 0001 Ball crank 24 1 16073430003014 Spiral tensioning pin 25 1 10400402 Spindle nut 26 1 10400403 Washer 27 1 16193300005010 Screw 28 1 10400446 Guide bar 29 3 16193300006016 Screw 31 1 16191200004010 Screw 33 1 10400406 Adjustment bar 35 3 16193400005000 Nut 47 1 10400440 Guide element 59 3 16091500005035 Spindle nut with adjusting nut 70 2 51502116 Threaded pin 74 1 16191200006035 Ball bearing 75 1 16191200006012 Screw 76 1 10400438 Screw 82 2 10400407 Clamping piece 83 2 10400409 Felt 84 8 16191200004010 Felt clamp 85 2 16191200005016 Screw 88 2 10400410 Screw 90 2 10400408 Felt clamp 91 1 10400447 Felt 92 3 16191300005012 Setting bar 93 3 16193400005000 Threaded pin 49 WAEHELL MASCHINENMANUFAKTUR seit 1885 18 Drawings and legends 18 9 Tool skid Lock plate m 35 37 50 WAB
24. ELU 18 Drawings and legends 18 9 Tool skid Lock plate Part No Items Order No 11 5 16191200004010 13 1 10400413 15 1 51004040 0001 16 1 10400416 17 2 16063250005016 18 2 10400417 19 1 1606885A040408 20 1 51507040 0001 21 1 51004015 0006 22 1 51006555 0021 23 1 10400423 24 2 51502517 25 4 16191200005016 26 1 10400426 27 1 51004035 0011 30 1 51507041 0001 31 1 16073430003024 32 1 51502131 33 1 10400433 34 1 51006545 0004 35 1 10400435 36 1 10400436 37 1 51004020 0004 53 1 51502009 54 1 16191200003010 MASCHINENMANUFAKTUR seit 1885 Description Screw Lock plate Keylock switch Clasp nut Pin Guide bar Parallel key Switch lever Washer Flange Sleeve Lubrication nipple Screw Pinion Dial Hand wheel Spiral tensioning pin Steel ball Scale ring Flange Sleeve Intermediate gear Washer Pressure spring Screw 51 WAHELLU MASCHINENMANUFAKTUR seit 1885 18 Drawings and legends 18 10 Tool skid Longitudinal skid 20 18 52 AI 52 WABELU MASCHINENMANUFAKTUR seit 1885 18 Drawings and legends 18 10 Tool skid Longitudinal skid PartNo Items Order No Description 3 1 10400505 Clamping ring 4 1 10400502 Guide ring 5 1 10400501 Longitudinal skid lower section 6 1 10400507 Longitudinal skid upper section 18 1 51502131 Steel ball 19 1 51502009 Pressure spring 20 1 51004035 0010 Dial 21 3 51007250 0001 Push piece 22 3 1609130000500
25. LLU MASCHINENMANUFAKTUR seit 1885 18 Drawings and legends 18 7 Change gear quadrant gus ER f 2 27 22 46 19 ZN 4 A13 16 25 28 20 41 CEA 42 13 46 WABELU 18 Drawings and legends 18 7 Change gear quadrant Part No Items Order No 13 3 51006580 0004 14 1 10600214 16 2 1606885A050325 19 1 10400301 20 1 51004633 0001 21 2 16155700008000 22 2 10600222 23 2 51006525 00011 24 3 51004020 0010 25 2 51007016 0001 27 1 51004633 0002 28 2 1600000001 0201 38 2 16193400008000 39 2 51502518 41 1 10600241 42 2 51502320 44 1 51502323 46 3 16143900008000 51006530 0001 1 51006530 00021 51006535 0001 1 51006540 0001 51006540 00021 51006545 0003 51006545 0001 51006555 0001 51006555 0004 51006560 0001 1 51006565 0001 MASCHINENMANUFAKTUR seit 1885 Description Toothed belt wheel Z48 Sleeve Parallel key Change gear quadrant Change gear bolt long Nut Washer Toothed belt wheel Z14 Washer Change gear sleeve Change gear bolt short Washer Nut Lubrication nipple Setting screw Gear belt Gear belt Nut Toothed belt wheel Z16 Toothed belt wheel Z18 Toothed belt wheel Z20 Toothed belt wheel Z22 Toothed belt wheel Z24 Toothed belt wheel Z26 Toothed belt wheel Z28 Toothed belt wheel Z32 Toothed belt wheel Z34 Toothed belt wheel Z36 Toothed belt wheel Z40 47 WA
26. afety screw 5 2 16173800006012 Safety screw 6 4 16191200005012 Screw 7 4 16112500004000 Washer 8 4 16193400004000 Nut 9 4 16191200004010 Screw 10 1 16193400006000 Nut 39 WAHELLU MASCHINENMANUFAKTUR seit 1885 18 18 3 40 41 42 39 40 Drawings and legends Headstock Items po N WoO PO 90 32 34 T Order No 10400104 51502517 51502108 10400105 10400107 10400106 16191200006012 16196500006014 10400109 10400110 10400111 10400112 10400113 51007250 0001 16091300006006 1606885A 100670 16191200008035 16112500008001 16191200008030 10400190 Description Headstock Lubrication nipple Tapered roller bearing Flange Oil scraper ring Main spindle Screw Screw Flange Sleeve Toothed wheel Gear wheel Nut Push piece Threaded pin Parallel key Screw Washer Screw Bush with collar WABELU MASCHINENMANUFAKTUR seit 1885 18 Drawings and legends 18 4 Headstock Transmission PartNo Items Order No Description 8 1 10600117 Gear wheel 24 2 51502113 Ball bearing 25 1 10600116 Sleeve 26 1 10600109 Axes 27 1 16047200032000 Securing ring 28 1 51004020 0022 Pressure washer 29 1 10400129 Transmission lever 30 1 10400130 Washer 31 1 1619340001 0000 Nut 32 1 51006750 0004 Centering ring 33 1 51502308 Belt 34 1 51502315 Belt 35 1 16191200008025 Screw 36 1 16112500008001 Washer 4
27. arrying out maintenance and cleaning work the machine must be switched off and the grounded plug pulled out 15 Set up work is only to be carried out with the machine switched off 16 Do not reach into the operating machine 17 Always switch the machine off when you are not using it 18 Remain with the machine until it has come to a standstill WABELU MASCHINENMANUFAKTUR seit 1885 1 Important safety notes 1 4 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 20 Protect the machine from damp 21 Constantly check the machine for damages Replace damaged parts only with original parts and have these replaced by a specialist The guarantee and warranty is voided if accessories and replacement parts are use that are not designed for the machine 22 To avoid insufficient lighting we recommend setting up a light source that provides a value of at least 500 Lux at the tool s cutting edge 23 Do not remove the generated shavings with your hand Use the appropriate tools hand held sweeper hook brush 24 Tools and work pieces may never be changed when the machine is running 25 Do not brake work pieces and bush using your hand or another object 26 Never leave the chuck key fitted even when not in operation 27
28. ch spindle right left T1 Speedometer T2 Thermistor W1 Coil 1 w2 Coil 2 57 WAHELLU MASCHINENMANUFAKTUR seit 1885 20 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 If the shavings tank with spray protection wall is secured to another suitable surface the four through holes must be bored into the surface by the client For the positions of the four drilled holes for the lathe or shavings tank with spray protection wall see the diagram The diameter of the through holes in the surface must be at least 9 mm 58 WABELU MASCHINENMANUFAKTUR seit 1885 20 Shavings tank with spray protection wall optional 20 2 Mounting the shavings tank with spray protection wall on the tool cabinet optional a shavings tank with spray protection wall 2 is positioned as shown on the tool cabinet 1 screws and washers required for assembly are included in the scope of delivery To screw the shavings tank with spray protection wall to the tool cabinet proceed as follows 1 Place the lathe carefully onto the panel 3 and align along the fixing holes 2 Combine each screw with a washer 3 Push the screws from below thro
29. d 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 in the serial version meets the following relevant regulations EU Machine Directive 2006 42 EC EMC Directive 2004 108 EC EU Low Voltage Directive 2006 95 EC In order to fulfil implement the requirements of the directives named above the already published and applicable standards were drawn upon EN ISO 12100 2010 DIN EN 60204 1 2006 EN ISO 23125 2010 Proxy for the compilation of the technical documentation is the operational head of the above named manufacturer Mr Christoph Schneider D 54673 Neuerburg 2014 Place and date of issue ehm Operational head Christoph Schneider WABELU MASCHINENMANUFAKTUR seit 1885 1 Important safety notes 1 1 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 1 2 Improper and incorrect use The lathes described in these operating instructions have been developed and manufactured for the purpose named above Walter Blombach GmbH accepts no responsibility for property damage and personal injury caused as a result of not intended and incorrect
30. e rear on a flat guide The skid is held onto the bed from below with the guide bar 9 and can be set to without play using the setting bar 12 If adjustment to the setting bar 12 is required please proceed as follows 1 Undo the hexagonal nuts 11 2 Using an Allen key tighten the threaded pins 10 in such a way that the skid is still able to move easily 3 After setting tighten the hexagonal nuts 11 back up again Clamping for face turning and cutting work Use the Allen head screw 6 to clamp the clamping piece 8 against the underside of the prismatic guide The tool skid can no longer be moved in the longitudinal direction WAHELLU MASCHINENMANUFAKTUR seit 1885 12 Tool skid Transverse skid The dovetail guide of the transverse skid can be adjusted If adjustment is required please proceed as follows 1 2 Undo the hexagonal nuts 5 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 After adjustment tighten the hexagonal nuts 5 back up again Any axial play of the spindle 13 in the spindle bearing 14 that may occur can be adjusted If adjustment is required please proceed as follows 1 2 3 4 Undo the threaded pins 3 Rotate the dial 2 clockwise in such a way that no axial play remains Tighten the threaded pins 3 back up again After adjustment the spindle 13 should still be easy to turn Th
31. e tensioned as short as possible and at a right angle to the rotational axis Inner lathe chisel 6 a 15 used for hollowing out drilled holes Tension as short as possible to prevent the occurrence of turning steel vibrations untidy surface a As a result of the forces exerted on the turning steel the steel must be short and secured firmly If the lever arm is too long the lathe chisel will bend and spring back The cutting edge will penetrate the work piece unevenly and result in a bumpy surface The turning steel is to be aligned with the center of the turning element checking of the height to the center of the work piece is carried out with the help of the turning center point in the tailstock The height position of the turning steel is achieved by adding even sheets WAHELLU MASCHINENMANUFAKTUR seit 1885 6 Thread cutting and automatic feed 6 1 Thread cutting thread turning steel is a moulded turning steel with the profile of the thread to be cut Itis 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 In order to obtain the correct position of thread flanks to the work piece axis place the grinding gauge up against the work piece and use it to set the turning steel Figure 1 To do this push the gauge up to both flanks of the turning steel one after another Figure 1 Setting
32. ed card a Polystyrene without Freon a Polyethylene foil Timber as single use pallet untreated Euro pallet multiple use packaging If you no longer need the items or you do not want to reuse them dispose of these items at the officially recognized recycling points The machine is manufactured in such a way that 98 of the used materials that can be recycled for example steel cast iron aluminium and only 2 are chemical materials e g cable sleeves of electrical cables PCBs If you have any difficulties in disposing of these parts properly we would be happy to help with prior agreement we will take back the machine in full and dispose of it You must however cover the costs of sending it to us wabeco rs de Walter Blombach GmbH Tel 49 0 2191 597 0 42899 Remscheid Fax 49 0 2191 597 40 Am Blaffertsberg 13 E Mail info wabeco remscheid de Germany WABELU MASCHINENMANUFAKTUR seit 1885 Contents Declaration of conformity for D4000 6 1 Important safety notes 7 1 1 Intended use 7 1 2 Improper incorrect use 7 1 3 Modifications to the machine 7 1 4 Safety regulations for proper use 7 1 5 Safety features 10 1 6 Explanations of the symbols 10 2 Delivery and set up 11 2 1 Transporting the machine 12 3 Putting into operation 13 4 Specifications regarding the machine 13 4 1 Identification of the model 13 4 2 Noise emission declaration 13 4 3 Technical data 14 4 4 Dimensions Front view 15 4 5 Dimensi
33. ed 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 Gear cover hood Always keep the gear cover hood closed The gear cover hood may only be opened by a trained person with a special key and when the grounded plug has been pulled out of the socket a ON OFF switch with under voltage trigger The ON OFF switch is fitted with an under voltage trigger thus in the event of a power failure the machine does not switch itself back on automatically This prevents risks caused by the unexpected motion of the spindle Emergency off switch The emergency off switch acts to quickly stop the machine Overload protection The machine is fitted with an overload protection feature This overload protection feature switches the main drive motor off automatically when the machine is overloaded The machine can only then be Switched on after a waiting period 1 6 Explanations of the symbols With an emission noise level as of 80 dB A at the workplace ear defenders must be worn Caution Always pull the power plug prior to any maintenance work Read the operating instructions prior to initial operation or maintenance work Caution Dangerous electric voltage WABELU MASCHINENMANUFAKTUR seit 1885
34. enter point and at the same time turn the chuck key clockwise 5 When the coil has caught turning jaw 1 insert turning jaw 2 into guide 2 6 Repeatthe procedure with jaws 2 3 and 4 for a four jaw lathe chuck 7 Then visually check the positions of the jaws These must meet centrally Mounting the drilling jaws 1 If you wish to use the drilling jaws again the process is the repeated in the same order 2 Three jaw lathe chuck First jaw 1 then 2 then 3 3 Four jaw lathe chuck First jaw 1 then 2 then 3 then 4 31 WAHELLU MASCHINENMANUFAKTUR seit 1885 16 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 closed Emergency off switch not unlocked Close the chuck protection hood Unlock the emergency off switch Direction of rotation has not been selected Select the direction of rotation at the turn switch Vibrations e g by transportation have caused the plugged contacts of the drive motor 1 4 kW board to come undone Pull the power plug Remove the cover sheet of the electronic housing and check all plugged contacts Main spindle motor no longer starts after the unlocking of the emergency off switch Motor controller must be unlocked For machines with a 1 4 kW drive
35. ention should be paid to ensure that the nozzle does not come into contact with the cutting tool 21 7 Controlling the flow of coolant using the coolant shut off valve Coolant shut off valve in the open position gt Maximum coolant flow Rotation of the coolant shut off valve clockwise gt Flow is reduced Coolant shut off valve in the closed position 2 Coolant flow stopped 65 WAHELLU MASCHINENMANUFAKTUR seit 1885 21 Coolant system optional 21 8 Drawing and legend Part No 2 1 2 2 2 3 2 4 2 5 2 6 3 1 4 1 4 2 66 Items 1 po B N HR LR a Order No 51401163 0001 51500119 51504320 51504218 51504318 51400400 0001 51504349 51502507 16191200006016 16112500006001 16191200004010 16112500004000 16193400004000 51400235 0001 Description Coolant system tank and two shelf inserts Coolant pump Screw fitted hose bush PVC fabric hose Screw fitted hose bush Bracket Collar Coolant hose with shut off valve Screw Washer Screw Washer Nut Spray protection wall 1060x445 WABELU MASCHINENMANUFAKTUR seit 1885 21 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 1 1 51400607 0001 Panel 2 1 16193300008016 Screw 2 1 9 16112500008001 Washer 2 2 5
36. ere are scale rings fitted to enable you to read of the distances 28 One interval on the scale ring 4 of the transverse skid represents a 0 05 mm distance which corresponds to the same chip removal on the work piece thus in reality the skid is only adjusted by 0 025 mm but the work piece diameter changes by 0 05 mm One turn of the ball crank 1 on the transverse skid corresponds to 1 mm of travel but a change of 2 mm to the diameter of the work piece One scale mark on the scale ring 16 of the tool skid represents a distance of 1 mm One turn of the hand wheel 15 corresponds to a distance of 30 mm WABELU MASCHINENMANUFAKTUR seit 1885 13 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 rotation is for example suitable for turning short tapers a In order to accurately read this setting a scale is engraved on the guide ring 4 zero mark is located on the transverse skid upper section The dovetail guide of the longitudinal skid can be adjusted If adjustment is required please proceed as follows 1 Undo the hexagonal nuts 2 2 Using an Allen key tighten the threaded pins 1 in such a way that the skid can still be moved easily using the ball crank 7 3 After setting tighten the hexagonal n
37. eve has a millimetre scale To read off the distance of travel of the tailstock sleeve there is a scale ring 9 One mark on the scale corresponds to an adjustment of 0 05 mm One turn of the ball crank 5 corresponds to a distance of 2 mm Centre point drill or drill chucks are automatically ejected when turning back Tool holder There is an inside cone MK 2 which is designed to hold tools and is incorporated in the sleeve 1 Tightening the clamping lever 2 ensures that the sleeve may be easily clamped in any position sleeve is moved axially by the hand crank 5 by way of the threaded spindle 4 30 WABELU MASCHINENMANUFAKTUR seit 1885 15 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 Do not attempt to clamp work pieces that are over the permitted clamping range clamping force is thus too low and the jaws may come undone The maximum revolution range specified on the lathe chuck may not be exceeded Mounting the jaws 1 The jaws and guides are numbered from 1 3 or 1 4 2 Open the lathe chuck with the key in such a way that the drilling jaws are released sequence 3 2 10r4 3 2 1 Insert turning jaw 1 into guide 1 4 Push turning jaw 1 in the direction of the chuck c
38. 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 Setting for left thread Undo the clamping screw 2 Swivel the tumbler gear 1 to the left so that the toothed wheel 3 comes into contact with the toothed wheel 5 of the main spindle With the main spindle in the same direction of rotation the skid moves away from the lathe chuck and towards the tailstock 21 472142 MASCHINENMANUFAKTUR seit 1885 6 Thread cutting and automatic feed 6 3 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 Table for thread cutting Special accessories The toothed wheels that belong to the scope of delivery are identified according to the number of teeth e g 48 stands for 48 teeth To thread cut as of a gradient of 0 4 mm B1 and B2 must be removed completely Table for automatic longitudinal feed mm c 0 085 0 16 A1 48 48 A2 14 18 B1 14 20 B2 48 48 48 48 C1 16 16 D 140 140 120 120 F 12
39. he turning steel moves parallel to the axis of the work piece To rough it is advantageous to use straight or curved turning steels finish use sharp or wide turning steels Face turning The processing of end planes is referred to as face turning When face turning the turning steel is moved at right angles to the rotating axis of the turning element The tool skid should be locked when doing so The main cutting edge of the turning steel is to be set precisely to the center so that the turning element center has no nose curved turning steel is used for face turning WABELU MASCHINENMANUFAKTUR seit 1885 5 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 For longitudinal and face turning a used for finishing creating a clean surface External thread lathe chisel 4 Is used for cutting external threads Narrow square nose cutting tool 5 15 used to cut grooves and cut off work pieces Attention should be paid to the precise height of the center of the turning steel Work with low revolutions and cool the tool cooling via drilling oil or emulsion acts as lubrication and removal of shavings The cutting steel is to b
40. ing work pieces or vices Screws for clamping the milling machine table Screw for connecting the tensioning bracket with the transverse skid MON RF Nut for securing the tensioning bracket to the transverse skid 23 3 Feed motion of the milling machine table a Use the crank 1 to move the milling machine table in the y axis vertical Use the scale ring 2 to read off the distance of travel Oneinterval on the scale represents a distance of 0 05 mm One full turn of the hand wheel is the same as a skid distance of 1 mm The distance of travel of the milling machine table in the x axis horizontal is carried out by adjusting the transverse skid 71 WAHELLU 23 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 To do this the skid should be moved during the setting process and checked for play and appropriate ease of movement 3 When the threaded pins 5 are set correctly tighten the lock nuts 4 back up again Only set the threaded pins 5 if they are in the range of the counter guide To do this the skid may need to be moved into this area Otherwise the dovetail guide may jam and this may cause damages 23 5 Alignment of the milling machine table If the milling machine table has been mo
41. iscosity of 100 mm 2 6 for oiling 24 WABELU MASCHINENMANUFAKTUR seit 1885 8 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 a Dovetail guide Transverse skid Dovetail guide Longitudinal skid a 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 All other lubrication points are lubricated with a grease press at the designated lubrication nipples ici TTE 1 1 V 1 B every 8 hours of operation 2 every 8 hours of operation The spindle bearing does not need to be lubricated since the ball bearings have a closed construction form and the bearings have been supplied at the factory with sufficient grease for the lifetime of the machine 25 WABELU MASCHINENMANUFAKTUR seit 1885 9 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 Undo the stud screw 1 in the setting nut 2 3 The setting nut 2 is located at the rear end of the main spindle 4 Rotate the setting nu
42. motor the motor must be switched on again using the ON OFF switch after the emergency off switch is unlocked After unlocking wait approximately 5 seconds before switching the machine on The drive motor 1 4 kW experiences skips during operation Tool skid cannot be moved or can only be moved with considerable force Carbon brushes and collector of the drive motor are contaminated Clean the carbon brushes and collector of the drive motor with a piece of coarse sandpaper See Maintenance section Carbon brushes are worn Clamping of the tool skid is on Guide play is set too narrowly Replace carbon brushes with new ones Open the clamping Adapt the guide play 32 WABELU MASCHINENMANUFAKTUR seit 1885 16 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 be moved with considerable force Rust on work pieces of machine parts when using coolant lubrication Play of the trapezoidal threaded nut is set too narrowly only transverse skid Wrong coolant set Adapt the play of the trapezoidal threaded nut Check the mixing ratio of the coolant and correct if required never cool with water alone Tool holder cannot be inserted into the main spindle reducing sleeve of the main spindle An incorrect tool taper of
43. ons Side view 15 4 6 Revolution selection 16 4 7 Diagram for reading off the revolutions 16 4 8 Revolution changer 17 4 9 Electrical equipment 18 5 Achieving optimum results 18 and avoiding incorrect usage 6 Thread cutting and automatic feed 20 6 1 Thread cutting 20 6 2 Tumbler gear drive 21 6 3 Use of change gears 22 7 Maintenance 24 8 Lubrication of the machine 24 9 Readjusting the main spindle 26 10 Overload coupling 26 11 Readjustment of the bearing clearance of the lead screw 27 12 Tool skid Transverse skid 27 WABELU MASCHINENMANUFAKTUR seit 1885 Contents 13 Tool skid Longitudinal skid 29 14 Tailstock 30 15 3 and 4 jaw lathe chuck 31 16 Operational faults and the elimination of such 32 17 Operating elements 35 18 Drawings and legends 36 18 1 Electronic console 36 18 2 Protective hood drive 1 4 KW motor 39 18 3 Headstock 40 18 4 Headstock Transmission 41 18 5 Headstock Tumbler gear 42 18 6 Bed with lead screw 44 18 7 Change gear quadrant 46 18 8 Tool skid Transverse skid 48 18 9 Tool skid Lock plate 50 18 10 Tool skid Longitudinal skid 52 18 11 Tailstock 54 19 Circuit diagram 56 19 1 for 1 4 kW motor 56 19 2 Key for Circuit diagram 57 20 Shavings tank with spray protection wall optional 58 20 1 Setting up the shavings tank with spray protection wall 58 20 2 Mounting the shavings tank with spray protection wall on 59 tool machine cabinet optional 20 3 Drawing and legend
44. or of the machine is to ensure that at least one copy of the operating instructions is stored in the immediate vicinity of the machine and available to the people who work with the machine 4 The operator is to ensure that the safety and danger notifications on the machine are observed and that the signs are kept in a legible state 5 Do not work without goggles 6 Wear close fitting clothing and if you have long hair wear a hair net Do not wear loose fitting or loose items ties shirt sleeves jewellery etc 7 Gloves may not be worn 8 In the event of an emission noise level as of 80 dB A at the workplace ear defenders must be worn 9 The machine may not operate without supervision 10 Secure your machine in such a way that it cannot be switched on by children Persons who have not been trained may not operate the machine 11 Before using the machine make sure it is in good working condition Pay special attention to any damage to the grounded plug or the electrical connections Never operate the machine with a defective crushed or exposed cable 12 Plug the grounded plug into a suitable socket for the machine The cable for the machine may only be connected to a safety socket or a connection box Have the safety socket or connection box checked by an electrical specialist before hand 13 The safety socket or connection box must be close enough to the machine that the power cable is not under strain 14 When c
45. ronic console 70 80 PartNo Items Order No Description 57 1 51001015 00021 Board holder with guide rails 59 6 16196500004008 Screw 60 1 51501402 Control board 63 2 16179910006020 Screw 64 1 51500102 0002 Motor 65 1 51004020 0003 Eccentric tappet 66 1 16191300005006 Threaded pin 67 1 51500619 End switch 70 1 51400405 0001 Cover plate 80 4 16191200004010 Screw 37 WABECO MASCHINENMANUFAKTUR seit 1885 18 18 1 Part No 46 47 47 1 48 56 61 62 74 75 76 77 78 79 38 Drawings and legends Electronic console Items 1 PO N NO a ND N 4 N m d am x A 56 79 78 77 76 15 N69 Order No 51400403 0001 16191200004010 16112500004000 51004010 0010 51400406 0001 160705A0010000 16191200005020 16191200006012 16112500006001 16191200004016 51501304 16167980004000 16193400004000 N Description Chuck protective hood Screw Washer Guide rod Electronic housing Adjusting ring Screw Screw Washer Screw Symbol for earthed connection Fanned washer Nut WABELU MASCHINENMANUFAKTUR seit 1885 18 Drawings and legends 18 2 Protective hood drive 1 4 kW motor 5 Q0 1 7 2 Part No Items Order No Description 1 1 51400401 0001 Protective hood drive 2 1 51400404 0001 Protective plate lead screw drive 3 1 51400485 0001 Protective plate spindle aperture 4 1 51508001 Key KW 4 for s
46. see diagram The diameter of the through holes in the surface must be at least 9 mm 4 lt 21 2 Mounting of the coolant system to the tool cabinet optional The coolant system 2 is positioned as shown on the tool cabinet 1 the panel 3 is not important in this stage a The screws and washers required for assembly are included in the scope of delivery To screw the coolant system to the tool cabinet proceed as follows 1 Combine each hexagon socket screw with a washer 2 Open the doors of the tool cabinet 3 Push the screws from below through the bored holes in the tool cabinet into the fixture threaded sockets and tighten using an Allen key of size 6 WABECO MASCHINENMANUFAKTUR seit 1885 21 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 2 3 62 Place the lathe carefully onto the panel 3 and align along the fixing holes Combine each hexagon socket screw with a washer Push the screws from below through the fixing holes in the panel 3 and into the fixture thread on the bed of the lathe and tighten using a size 18 combination wrench Place the lathe with the panel carefully onto the coolant system and align along the fixing holes Remove both inlay sheets out of the coolant system Combine each nut with a washer and screw from below the nuts onto out of the panel 3
47. t 2 clockwise until the bearings run free again it must be possible to rotate the main spindle by hand easily e Tighten the stud screw 1 back up again 6 Ifthe tapered roller bearings are set too tightly they will quickly become unusable 7 Close the gear cover hood by tightening the safety screw with the supplied special key 10 Overload coupling In order to prevent risks to the user and damage to the machine an overload coupling has been fitted to the lead screw The overload coupling 11 is effective a When the feed is overloaded When contact is made with an end stopper in the longitudinal direction If adjustment is required proceed as follows 1 The overload coupling 11 is set using the hexagonal nuts 38 and countered with the nut 46 26 WABELU MASCHINENMANUFAKTUR seit 1885 11 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 Undo the outer of the two capstan nuts 5 2 Turn the inner capstan nut 4 clockwise against the axial bearing 3 until the lead screw 1 has no more axial play 3 Then counter the outer capstan nut 5 against the inner capstan nut 4 12 Tool skid Transverse skid The tool skid is positioned at the front on a prismatic guide and at th
48. the tool holder has been used in combination with the reducing sleeve Only use the appropriate tool holders for the machine Inner cone of the reducing sleeve or outer cone of the tool holder is contaminated Clean the relevant cone Tool overheated Revolutions too high Reduce the revolutions Feed too high Reduce the feed Working without coolant Use coolant Insufficient coolant feed at the cutting edge Tool blunt Align the coolant hose correctly Sharpen tool or use a new tool Increased friction caused by shaving build up in the tensioning groove of the tool drilling work Remove the shavings from the hole more frequently withdraw Use a coated tool Wash the processing area with coolant Unsuitable tool chosen for the material to be processed Only use the suitable tool for the relevant material 33 WABELU MASCHINENMANUFAKTUR seit 1885 16 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 Now crank the tailstock sleeve back to push the tool out Use of tools without ejector lugs is possible by screwing a suitable threaded pin into place which extends the
49. ual feed spindles for easy operation Check all electronic operating elements for example ON OFF switch emergency off switch potentiometer bush protection hood etc for functionality 4 Specifications regarding the machine 41 Identification of the model The precise model designation of your machine can be found on the type plate attached to the machine 4 2 Noise emission declaration Noise emission declaration in accordance with DIN EN ISO 3744 Emission values in idle Emission noise level at the workplace at 50 70 3 dB A at 100 78 2 dB A Sound power level at 50 96 76 8 dB A at 100 86 6 dB A With an emission noise level as of 80 dB A at the workplace ear defenders must be worn WAHELLU MASCHINENMANUFAKTUR seit 1885 4 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 Machine accuracy Concentricity of the spindle lug 0 005 mm Cylindrical rotation on 100 mm overhung 0 01 mm 2 with simple turning on 300 mm between 0 015 mm Headstock Main spindle aperture 20 mm Taper in main spindle MK3 Main spindle lug According to DIN 6350
50. ugh the fixing holes in the panel 3 and into the fixture thread on the bed of the lathe and tighten using a size 13 combination wrench 4 Place the lathe with panel carefully onto the shavings tank with spray protection wall and align along the fixing holes 5 Open the doors of the tool cabinet 6 Combine each nut with a washer and screw from below the nuts onto out of the panel 3 protruding threaded bolt 7 Tighten the four nuts using a size 18 combination wrench 59 WAEHELL MASCHINENMANUFAKTUR seit 1885 20 Shavings tank with spray protection wall optional 20 3 Drawing and legend V Part No Items Order No 1 51400235 0001 51400607 0001 51400484 0001 16193400008000 16112500008001 16193300008020 16193400004000 16112500004000 16191200004010 WD 60 Description Spray protection wall Panel Shavings tank Nut Washer Screw Nut Washer Screw WABELU MASCHINENMANUFAKTUR seit 1885 21 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 For the positions of the four fixtures threaded sockets thread M8 of the coolant system
51. und 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 Then switch on at the ON OFF switch The ON OFF switch must also be switched on again after the power is interrupted a change the direction of rotation of the main drive motor the turn switch must briefly rest at the 0 position to allow the relays on the control board enough time to switch n the event of the main drive motor being overloaded it will switch itself off automatically The main drive motor can only be switched back on again after a short waiting period p Achieving optimum results and avoiding incorrect usage Use of suitable processing tools Adaptation of revolution setting and feed to the material work piece and tool Tension tools as far into the tool holder as possible short projecting length Tension turning element as far into the chuck as possible short projecting length Support length pieces with a tailstock or bezel use of coolant and lubrication to increase the durability of the tool improve surface quality and accuracy Clamp processing tools and turning elements on a clean clamping surface Lubricate machine sufficiently a Setthe bearing clearance and guides correctly Longitudinal turning For longitudinal turning t
52. uts 2 back up again Any axial play of the spindle 8 in the spindle bearing 11 that may occur can be adjusted If adjustment is required please proceed as follows 1 Undo the threaded pins 9 2 Rotate the dial 6 clockwise in such a way that no axial play remains 3 Tighten the threaded pins 9 back up again 4 After adjustment the spindle 8 should still be easy to turn To read off the distance of travel of the longitudinal skid there is a scale ring 10 mark on the scale corresponds to an adjustment of 0 05 mm Since the longitudinal skid does not work with diameters this 0 05 mm corresponds to the actual distance One turn of the ball crank 7 corresponds to a distance of 1 mm 29 WAHELLU MASCHINENMANUFAKTUR seit 1885 14 Tailstock a 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 To do this proceed as follows 1 Undo the hexagonal nut 6 2 With the help of both threaded pins 8 slide the upper section into the required direction The central position of the tailstock is shown by the scale mark 7 Turn a sample to see whether the work piece is cylindrical correct the tailstock setting if necessary Tailstock sleeve The solid tailstock sle
53. ved unintentionally angle of T groove to x axis this must first be realigned To do this open both screws 7 align the table and then tighten both screws up again 7 For the alignment work always use a dial gauge if you have one 23 6 Lubrication of the tensioning bracket with milling machine table Use a class 2NLGI multi purpose grease for lubrication Use lubricating oil with a viscosity of 100mm s for lubrication a Prior to each use Lubricate the spindle bearing at the lubrication nipple 3 using a grease press Grease the feed spindle accessible from the front Oil the dovetail guide with lubrication oil using an oil can 72 WABELU MASCHINENMANUFAKTUR seit 1885 23 Tensioning bracket with milling machine table optional 23 7 Drawing and legend he 8 9 e9 73 WAHELLU MASCHINENMANUFAKTUR seit 1885 23 Tensioning bracket with milling machine table optional 23 7 Drawing and legend Part No Items Order No 1 1 51003790 0001 2 1 51400242 0001 1 3 1 51004016 0004 4 1 51007016 0002 5 5 51001016 0006 6 3 16143900006000 7 3 16091500006016 8 1 51003000 0001 9 1 16093800010070 10 1 51006831 00332 11 1 51001016 00081 12 1 16112500008001 13 1 16193400008000 14 1 16193400010000 15 1 16112500010000 16 1 51003003 0001 17 2 16191200006012 18 1 51502131 19 1 51502009 20 1 51507023 0001 21 1 16073430003014 22 1 16147100025000 23 1 5

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