Please read before start-up! Operating Instructions
Contents
1. 39 12 Drawing and list of parts 12 10 Drive hs high speed with 2 0 kW motor Part no 10600501 10600502 11820009 10600504 10600505 11700031 11800018 10600508 10600509 11700059 10600511 10600512 10600513 11700103 11700053 10600516 10600517 CONDO O 0 WBN gt O NO O OWN O 40 Order no Description Switch box Belt pulley main spindle Drive belt motor Belt pulley motor Clamping disc Screw Motor high speed Protective cover Retaining plate Fastening screw Retaining plate holder Shaft Bearing piece Fastening screw Hexagon nut Stud bolt Threaded pin j AN q lt is WWABECO nX 12 Drawing and list of parts 12 11 CNC drive X axis Part no NOOR OWN gt 18 Pieces Order no Description 1 10600901 Protective cover 2 10600902 Spacer 1 1184001 1 Ball ended crank 1 11700023 Spiral clamping pin 1 11850002 Spring 4 11700046 Hexagon socket screw 1 10600903 Belt pulley 1 11810004 Ball 1 10600904 Graduated collar 1 10600905 Motor holding plate 1 10600906 Clamping plate 1 10600907 Belt pulley 2 10600908 Flanged wheel 1 11700049 Spiral clamping pin 1 11820007 Toothed belt 2 11700031 Cylindrical screw 1 11800003 Stepping motor 1 10600908 Motor distance plate 2 11700050 Hexagon nut 4 11700018 Washer 4 11700019 Hexagon nut 18 ET 48 23 24 44 45 13 1 12 Drawing and list2. N rr 10600401 10600402 10600403 10600404 10600405 10600406 11700070 10600408 11810004 11850002 10600411 10600412 11700087 11700087 11700106 11700105 10600417 11700081 10600419 11810005 11840011 11700023 11840015 10600424 10600425 Description Upper part of tailstock Lower part of tailstock Shim Spindle sleeve Spindle Flange Hexagon socket screw Scale ring Steel ball Pressure spring Scale holder Pressure spring Threaded pin Threaded pin Hexagon bolt Threaded pin Washer Hexagon nut Scale tape Lubricating nipple Ball ended crank Spiral clamping pin Clamping lever Sleeve shim upper part Sleeve shim lower part 12 Drawing and list of parts 12 10 High speed drive with 2 0 kW motor SS sy X N A NC S S N x LAN 7A N a 1 f i FA z H Ng pa a 1 in Ka sA a A NG a fF SH les ATA ATS A AA QU 7 PNG 4 L PES t UP I MM a N pss v L 7 Pa b N N Faj b M P
3. In VA BECO 11155 Please read before start up Operating Instructions Universal Lathes Version of 09 2009 CC D6000 CC D6000 CA CC D6000 hs CC D6000 CA hs Walter Blombach GmbH Tool and Machine Factory D 42899 Remscheid Am Blaffertsberg 13 Phone 0049 2191 597 0 Fax 0049 2191 597 40 E Mail info wabeco remscheid de D 54673 Neuerburg WABECO Str 1 10 Phone 0049 6564 9697 0 Fax 0049 6564 9697 25 E Mail neuerburg wabeco remscheid de Internet www wabeco remscheid de Dear customer Congratulations on choosing the WABECO Universal Lathe We have taken great care in its manufacture and we have given it a thorough quality control test These operating instructions are to help you to work with it safely and properly Therefore please read the respective instructions carefully and pay attention to them After unpacking the machine please check to see if any kind of damage has occurred during transportation Any complaints must be made immediately Complaints made at a later date cannot be accepted If you have any questions or need any spare parts please quote the machine number located on the front of the motor see nameplate Duplications or copies of this document of any kind or of exerts require a written approval by WABECO Disposal of the lathe The transport and protective packaging are made up of the following materials corrugated cardboard polystyrene free of freon polyethylene foil
4. After making the adjustment the spindle must still be free to turn easily For calculating the travel path of the slide there is a large scale ring 17 with graduation marks on scale support 20 One scale mark corresponds to 0 05 mm of adjustment and this corresponds to the same amount chip removal from the work piece i e the actual slide travel amounts to 0 025mm only whereas the work piece diameter is reduced by 0 05mm One revolution of the ball ended crank corresponds to 2 mm but however the work piece diameter is changed by 0 4 mm 6 4 2 Longitudinal slide The longitudinal slide is clamped to the transversal slide upper part 52 by using the clamping ring 3 After loosening the hexagon nuts 62 the longitudinal slide can be pushed or turned along the transversal slide This is suitable for lathing short tapered pieces A scale is engraved on the guide ring 4 so that you can read the exact setting The zero mark is on the upper part of the transversal slide The dovetail guides of the longitudinal slide can be adjusted as described for the transversal slide The parts have a different numbering in the drawing hexagon nut 35 threaded pins 34 ball ended crank 23 Likewise as described in the case of the transversal slide the axial play of the spindle can be adjusted Here the parts are also numbered differently spindle 44 spindle bearings 45 threaded pin 51 scale support 49 14 6 6 4 2
5. 6 5 Description of assembly groups Longitudinal slide As described for the longitudinal slide the longitudinal slide is also provided with a reading scale for its travel path Here one scale mark corresponds to a feed motion of 0 05mm As the diameter is not taken into consideration with the longitudinal slide the feed motion of 0 05 mm corresponds to the actual path One revolution of the crank corresponds to a path of 2mm Tailstock The tailstock can be displaced along the lathe bed and may be locked in any position by tightening the hexagon nut 18 The tailstock consists of an upper and a lower part The upper part can be displaced up to 10 mm for turning long slim tapers To do so please proceed as follows Loosen the hexagon nut 18 and push the upper part in the desired direction with the help of the two threaded pins 16 The centre position of the tailstock is indicated by the lateral mark Find out by doing some trial turning if the work piece is cylindrical and correct the tailstock position if necessary Tailstock sleeve The solid tailstock sleeve which is provided with a millimetre scale 19 is designed in such way that the lathe centre drill barrel or chuck are automatically ejected during the backward motion Tool holder An inner taper MT 2 is available for holding the tool It is integrated in the sleeve 4 The sleeve can be clamped easily in any position by tightening the upper clamping lever The slee
6. 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 public recycling facilities 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 EC Conformity Declaration 5 1 Machine dimensions 6 1 1 D6000 6 1 2 D6000 hs 6 1 3 D6000 with coolant unit 7 1 4 CC D6000 7 2 Delivery and installation 8 3 Conditions for best results 8 4 Safety instructions 9 5 Start up and maintenance 9 5 1 Maintenance 9 5 2 Start up 10 5 3 Lubrication of the machine 10 5 4 Guidelines for the periodical maintenance of the machine 10 6 Description of assembly groups 11 6 1 Design features 11 6 2 Head stock 11 6 2 1 Main spindle 11 6 2 2 Electrical equipment 12 6 2 3 Speed regulation for 1 4 kW motor 12 6 2 4 Speed regulation for 2 0 kW motor 12 6 2 5 Speed transmission main spindle to lead screw 12 6 2 6 Tumbler gear adjustment 13 6 2 7 Protective cover for chuck 13 6 3 Bed with lead screw drive 13 6 3 1 Overload clutch 13 6 3 2 Setting the bearing p
7. the grinding jig is put against the work piece and the turning tool is adjusted in accordance with it For that purpose the jig is put against both flanks of the turning tool The feed of thread cutting tool is effected via the lead screw and must correspond to the thread pitch The change gears in the accessories connect the feed drive with the lead screw Putting on different combinations of toothed wheels allows to cut metric and inch RH and LH threads The different axis distances of the toothed wheels can be adjusted by pivoting the quadrant and by displacing the quadrant bolts The feed is switched on by means of the lever situated on the apron When cutting threads please make sure that the feed remains continuously switched on to ensure that the turning tool always returns to the same position if more than one cutting procedure is required After completion of the cutting procedure the cross slide disengages the tool because otherwise the flanks and cutting lips would get damaged The transversal slide is taken back to its home position when changing the sense of rotation of the motor by operating the reversing switch It is advisable to cut a 4 5 mm wide groove into the thread end in order to facilitate the disengaging of the tool In case of long thread diameters it is advisable to use the live centre to prevent the workpiece from being pushed to one side picture 1 Setting the thread cutting tool 17 7 Applications 7 2 2
8. 1 11700069 28 1 10600128 29 2 11810016 30 2 10600130 31 2 11700090 32 3 11700059 34 1 10600134 36 2 10600136 3 1 10600137 39 1 10600139 40 1 10600140 41 1 10600141 42 1 11700066 43 1 11800004 44 1 11800015 45 1 11800001 46 1 10600146 47 2 10600147 48 1 10600148 49 2 11700022 50 1 10600150 51 1 10600151 52 1 10600152 53 1 10600153 54 1 11700023 56 1 10600156 57 1 10600157 58 2 10600158 59 2 11700001 60 1 11800005 61 1 11700091 62 1 11700044 63 2 11700092 64 1 10600164 65 1 10600165 C 1 11700044 67 1 11800014 68 1 10600168 69 1 11700023 70 1 10600170 71 1 10600171 72 1 11800008 Description Bolt Toothed wheel Toothed belt wheel Bushing Washer Lubricating nipple Hexagon bolt Feather key Lever Needle bearing Bolt Stud bolt Countersunk screw Flange Bushing Toothed wheel Belt pulley Nut Thrust pad Stud bolt Potentiometer compl Reversing switch On OFF switch Chuck protective hood Toothed belt Angle joint Hexagon socket screw Clamping screw Clamping screw Setting ring Hexagonal piece Spiral clamping pin Steel box Steel elbow joint Circuit board holder Steel bolt Control electronics Setting ring Threaded pin Hexagon bolt Motor Eccentric Threaded pin Limit switch Protective hood Spiral clamping pin Cover plate Feather key Emergency OFF push button N ee Ses C0 ej O eed D Le C C0 O E gt C0 Sama Bed with lead screw drive 12
9. Application of change gears For automatic longitudinal turning there are two feed rates available 0 085 mm and 0 16 mm revolution The machine is delivered with the gears producing a feed of 0 085 mm revolution put on Putting on different combinations of gears enables you to cut metric threads ranging from 025 to 7 0 mm in pitch The same applies to inch threads ranging from 10 threads to 40 threads in pitch To wo wo ss e Da wo so wa CE rao 140 140 sao so seo 140 va DR as las px alala re 4 aa 20 0 20 Lo 140 wo sa 120 120 120 epu a se se se 150 20 a 2 39 wo Pe 3 a a0 36 a5 o 14 2 Lo 520 vm 120 14o tao sa 120 140 van tao 120 120 san 120 wo wo 40 3 BECO 152 ra Applications 7 2 2 Application of change gears for D6000 A2 and B2 front toothed wheel A1 and B1 rear toothed wheel Table for automatic longitudinal feed 19 TREE N65 Applications 7 2 3 Altering the feeds or thread pitches When altering the feeds or thread pitches proceed as follows g 2 Changing the feed from 0 085 mm to 0 16 mm Loosen set screw D of quadrant First loosen the hexagon socket screw at the front of the headstock and open the protective cover Loosen and remove the hexagon nuts and washers from bolts A and B Loosen the hexagon bolts A and B Remove the toothed belt connecting A
10. V D brown1 yellow green mains supply connection 44 P OU LVR EUS 13 Circuit diagram 13 3 Motor 1 4 kW with safety cabin This document shows all components of the electrical equipment including the mains connection fan connector switch operating voltage rectifier om manual CNC amplifier card B80 70 25 X 14 13 mains transformer 80VA limit switch a n Lo l operator doors T E KAG Y limit switch 1 spindle cover v ok pH main switch with low p main spindle voltage release blue brown 22i yellow green EI 3 E o en Q Q c A c c Mg ka 839 c E Da 5 O E R a 3 D reversing switch o E Ka Sontheimer S h Ped KAO ma RR 220k0 po Mills 0 O g E SI 18 o 3 o speed potentiometer motor plugs ma main spindle 5 6543 2 1 8335 od O a 5 coolant pump coolant 05 9 switch V09 M blue i 7 u a PL brown y li L PE yellow green emergency OFF 45 13 Circuit diagram 13 3 1 High speed motor 2 0 kW with safety cabin This document shows all components of the electrical equipment including the mains connection operating voltage fan connector switch amplifier card rectifier X manual CNC B80 70 25 Pa S 1 ay j 215 1 18 limit switch n A operator doors ee F limit switch B n cover spindle a HN motor connector box 5 1 l main spindle right le
11. and B Unscrew bolt B on the quadrant and the two toothed belt pulleys and remove them Remove toothed belt between drive wheel and A Remove both toothed belt pulleys Z 14 from bolts A and B and replace them by toothed belt pulley Z 18 or toothed belt pulley Z 20 respectively Mount bolt B together with both toothed belt pulleys to the quadrant screwing the bolt into the square nut located behind the quadrant Put on the toothed belt from B to C pull bolt B upwards until the toothed belt is stressed Then tighten bolt B Pull bolt A upwards until the toothed belt is stressed then tighten bolt A Pivot to the front until the toothed belt between drive shaft and bolt A is stressed tighten set screw D Mount the washers and nuts to A and B and tighten them Close the headstock cover and re tighten hexagon socket screw Changing the feed from 0 85 mm to a metric pitch of 1 5 mm a c Start as already described under pos 1 a c with the exception that the hexagon nut must be removed from the bolt C too as described under pos 1 b Remove the bushing and the toothed belt pulley 48 from bolt C Then first put the bushing and the toothed belt pulley Z 14 onto bolt C but make sure that the bushing precedes the tooth belt pulley Bolt B with toothed belt is needed for cutting very fine threads As toothed belt pulley Z14 is already put on bolt A you do not have to make any changes Put on the toothed belt between the drive wheel to b
12. bed Inside the headstock the main spindle is seated on two adjustable precision tapered roller bearings If readjustment of the bearings is required please proceed in the following manner 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 clockwise direction until the bearings run free of play again the main spindle can easily be turned by hand 3 Re tighten the locking screw Roller bearings adjusted too tightly become useless after a short period The spindle bore capacity is 20 mm For safety reasons the whole drive is completely covered with a protective hood and is fixed on to the headstock 11 6 Description of assembly groups 6 2 2 Electrical equipment 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 sealed contact plug can be connected directly to the 220 V mains supply via a sealed contact socket All 230V machines are fitted with a main switch with undervoltage release i e this switch must be switched on before the machine can be switched on via the reserving switch The main switch must also be switched on again following a power failure If you wish to change the sense of rotation of the motor by means of a reversing switch in the case of Electronic Lathe 10600 the reversing switch must remain in the O position for abou
13. clamp Felt Guide rail Threaded pin Nut 12 Drawing and list of parts 12 8 Lower part of tool slide for ball screw 36 Unum 12 Drawing and list of parts 12 8 Lower part of tool slide for ball screw Part no Pieces Order no Description 1 1 10600701 Lower part of cross slide 2 1 10600702 Upper part of cross slide 3 1 10600703 Adjustable gib 4 3 10600704 Thrust piece 5 3 11700102 Headless pin 6 1 11700019 Hexagon nut 7 1 10600705 Ball bearing nut 8 4 11700031 Hexagon socket screw 9 1 10600706 Spindle bear transversal slide 10 2 11810011 Ball bearing 11 1 10600707 Spindle holder 12 1 10600708 Ball screw 13 1 11700113 Woodruff key 15 2 10600709 Adjusting nut 36 2 10600710 Felt 37 2 10600711 Felt 38 2 10600712 Felt clamp 39 2 10600713 Felt clamp 40 8 11700026 Hexagon socket screw 41 1 10600714 lathe apron 42 2 11700033 Hexagon socket screw 43 1 10600715 Guide rail 44 1 10600716 Adjustable gib 45 6 11700041 Hexagon socket screw 46 4 11700087 Threaded pin 47 1 10600717 Clamping piece 48 1 11700037 Hexagon socket screw 49 1 10600718 Guide aid 50 1 11700078 Hexagon socket screw 51 1 10600719 Ball screw nut holder 52 4 11700114 Threaded pin 53 1 10600720 Ball screw nut 54 4 11700039 Hexagon socket screw 37 12 Drawing and list of parts 12 9 38 Tailstock Part no CONDO OB DON NI mm mr mr c cl cl Q O O XO NO 0 BB ON O 21 Pieces Order no mm cA N rr N o zr
14. 12 5 30 12 Drawing and list of parts 12 5 Bed with lead screw drive Part no Pieces Order no 1 1 10600201 2 5 10600202 3 1 11700031 4 1 10600204 4a 4 106002041 5 2 11700041 6 2 11810006 7 1 11700093 8 1 10600208 9 1 10600209 10 1 10600210 11 3 10600211 13 1 10600213 14 1 10600214 15 3 10600215 16 4 11700072 18 1 11700094 19 1 10600219 20 2 10600220 21 2 11700054 22 2 10600222 23 2 10600223 24 2 10600224 25 1 10600225 2 2 10600227 28 1 10600228 30 2 11840007 38 2 11700053 39 1 11810009 40 1 10600240 41 1 10600241 42 2 11820004 44 2 11820003 45 2 11700053 47 2 11810005 Description Bed Toothed rack Hexagon socket screw Support bearing rear Bushing Hexagon bolt Deep groove ball bearing Capstan nut Lead screw Support bearing front Bushing Shearing bushing Toothed belt pulley Bushing Washer Feather key Hexagon socket screw Change gear quadrant Change gear bolt Square nut Disc Toothed belt wheel Washer Bushing Change gear bolts Disc Knurled screw Hexagon nut Lubricating nipple Cover plate Set screw Toothed belt Toothed belt Hexagon socket screw Lubricating nipples 31 12 Drawing and list of parts 12 6 32 aiga sYa Ag Bed with lead screw drive for ball screw 3t NIT XE Part no co NOD O RB ON Pieces N mt sp PY ma Order no 10600601 10600602 11700077 11700070 10600603 10600604 11700072 11700108 10600
15. 2 Never take measurements on work pieces during the lathing process risk of accidents and damage to the measuring gauges 13 Do not wear loose clothing ties shirt sleeves jewellery etc 14 When working between centres always centre well in order to prevent the workpiece from being slung away In addition make sure that the locking screw of the tailstock is tightened 15 When using the automatic feed always take care that the cross support does not get in contact with the chuck or the tailstock 16 Never leave the machine alone when in operation 17 When machining wood use the lathe centre instead of the lathe chuck to support the work piece 18 The machine must be secured so that it cannot be switched on by children Make sure that other people do not operate the machine 19 Always keep the machine dry 20 Frequently check the machine for damage Any damaged parts must be replaced by original parts and are to be fitted by an expert or by us 9 Start up and maintenance 5 1 Maintenance The longtime serviceability is vitally dependent upon appropriate care The lathe needs to be cleaned after every turning job In case the lathe is to be installed in a moist cellar room all bare parts need to be oiled after use to avoid corrosion An overall and constant lubrication of all moving parts is highly significant In case of backlash inside the bearings or inside the guideways of the slides readjust in time to avoid the bearin
16. 564 9697 25 We hereby declare that the universal lathes specified below Universal lathes type D6000 D6000 hs with high speed motor CC D6000 CC D6000 hs with high speed motor meet the following regulation requirements for standard serie production directive for machines 2006 42 EG EMV directive 89 336 EWG In order to meet implement the requirements of the above mentioned directives the following applicable and previously published standards have been adhered to EN ISO 12100 1 EN ISO 12100 2 EN 12840 EN 60204 1 D 54673 Neuerburg City Uu Sehun Technical Director 1 Machine dimensions 1 1 D6000 COWIE CT NP Lx fixing holes M8 depth 20mm 1 2 D6000 hs high speed DIRT i Bi m MER RANA am EI 7 zu TU CUM a NN LL aaa daa ayyy al A 1 Machine dimensions 1 3 D6000 with coolant unit la i iil I Wiz Ep Zt Zz PIL li yt a aan aan NES at eS HD BLZ icm Z I 1 1 maim namia L EIB Ettr te coolant unit 1066 1 4 CC D6000 safety cabin order no 1060090 machine stand order no 10267 screen order n0 1140995 2 Delivery and installation The lathes are carefully packed in our factory Please check the following on delivery 1 2 whether the packaging has been d
17. 605 10600606 10600607 11700099 10600608 10600609 Description Bed Support bearing front Headless pin Hexagon socket screw Bushing Feed shaft Feather key Setting ring Coupling Pressure spring Clutch disc Spiral clamping pin Bearing cover Eccentric shaft 4 is WABECO m 12 Drawing and list of parts 12 6 Bed with lead screw drive for ball screw 15 1 11700024 Spiral clamping pin 16 1 11700109 Setting ring 17 2 11700049 Spiral clamping pin 18 1 11840016 Clamping lever 19 1 11810017 Ball bearing 20 2 11810018 Ball bearing 21 1 10600610 Guide bush pinion shaft 22 1 11700012 Circlip 23 1 10600611 Lead screw pinion shaft 24 1 11700110 Feather key 25 1 10600612 Pinion 26 2 11700023 Spiral clamping pin 27 1 10600613 Graduated collar 28 1 11840017 Knurled screw 29 1 11700024 Spiral clamping pin 30 1 11840014 Hand wheel 31 1 10600614 Pressure spring 32 4 11700107 Hexagon socket screw 33 1 10600615 Bearing rear 34 2 11810019 Ball bearing 35 1 10600615 Lead screw 36 1 11700111 Cylindrical pin 38 1 10600616 Bearing cover 39 2 11700112 Hexagon socket screw 40 4 11700041 Hexagon socket screw 41 1 11700113 Woodruff key of 1 10600617 Feed lever 58 1 11700072 Feather key 59 3 10600213 Toothed belt pulley 60 1 10600214 Bushing 61 2 10600222 Disc 62 1 10600220 Change gear bolt 63 1 10600227 Change gear bolt 64 2 11700054 Square nut 65 2 10600228 Disc 66 2 10600225 Bushing 67 2 11700072 Feather key 68 2 10600223 T
18. amaged and or whether the drilling and milling machine shows signs of damage in transit or if there is any other reason for complaint In this case we request your immediate notification Claims made at a later date cannot be accepted The lathes must be installed on an appropriate level and firm base This would be for example a base cabinet such as in our accessories programme a work bench strong enough to carry the weight of the machine without warping with an even surface see technical data and check with spirit level a Steel plate The lathe must be firmly screwed to the base Use the 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 are observed The machine should be installed in a well lighted area and electrical cables with earthed sockets and O conductors must be installed close to the machine so that the mains cable is not subject to any tension whatsoever The mains cable should be such that for example by means of a multiple socket a coolant unit can also be connected 3 Conditions for best results Fix the machine to 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 close as possible to the work piece Clamp the work pieces tightly and without vibrations Lo
19. ase gun and standard roller bearing grease 5 4 Guidelines for the periodical maintenance of the machine Daily Grease the lubrication 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 toothed belt and tighten as every 500 600 necessary operating hours Check the play inside the guideways and lead screws and adjust Check the bearing heat of the main spindle and the electric motor 10 6 Description of assembly groups 6 1 Design features e Solid large dimensioned grey cast iron machine bed e Sturdy cross ribbing makes the bed extremely stable and enables you to work without oscillations e The wide prismatic guide is ground e Transversal and longitudinal support with dovetail guides and adjustable gibs e All guides provided with a wiper for chips and dirt e Large dimensioned pivoting scale rings reading accuracy 0 05 mm e Main spindle is seated in adjustable taper roller bearings e Ground main spindle nose e Electronically infinitely adjustable spindle speeds e Clear and ergonomically arranged controls e Equipped with Emergency OFF push button e Main switch with undervoltage release e Motor switchable left right e Tailstock with its own prismatic guides e Large torque on main spindle via gear transmission 6 2 Headstock 6 2 1 Main spindle The headstock is firmly screwed to the machine
20. ch is fed in through the hollow work spindle from the gear side draw the collet chuck into the closer 22 lt m WABECO n 10 Lubrication coolant unit The lubrication coolant unit consists of 1 Tray with lubrication coolant tank which supplies the feed pump with lubrication coolant General content of 19 litres Feed pump with the following electrical data nominal voltage 230 V frequency 50 Hz nominal current input 0 4A nominal output 0 07 kW ON OFF switch and mains supply with a length of 2 m with earthed plug Adjustable flexible pressure hose with stop valve and nozzle for transporting the cooling lubricant to the machining area When using lubrication coolant especially water based emulsions a number of health and safety measures must be observed which we would like to recommend 1 Use concentrated products free of nitrites 2 Use concentrates without secondary amins 3 Use products with the lowest possible allergy potential When mixing a refill of cooling lubricant 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 nitrites 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 followin
21. ctness of the centre height of the turning tool Work at low rotational speed and cool the tool use drilling oil or emulsion for cooling serves for lubricating and for the removal of chips The parting tool is to be clamped as short as possible at 90 degrees to the workpiece Inside turning tool Used for the hollowing out of boreholes Clamp as short as possible in order to avoid vibration of the turning tool which might otherwise occur uneven surface T Applications 7 1 Longitudinal and transverse turning For the reason of the force effect at the turning chisel take care that the tool is short and tightly clamped If the lever arm is to long the turning chisel curves and springs back The cutting part enters uneven into the work piece and is producing a waved surface Take care that the turning chisel is directed to the centre of the work piece The height position in the work piece centre is regulated via the live lathe centre inside the tailstock The height position of the turning tool is achieved by using straight sheet steel 7 2 Thread cutting and automatic feed 7 2 1 Thread cutting The thread cutting tool is a shape turning tool with the profile of the thread to be cut It is ground according to jigs diagram 1 and must be adjusted exactly to the workpiece centre as otherwise the profile of the thread would be distorted In order to obtain the correct position of the thread flanks relating to the axis of the workpiece
22. de Adjusting nut for tool clamping plate a et ee O ET Ball ended crank for transversal slide adjustment Hand wheel for quick adjustment of the tool slide Clamping screw for clamping the tool slide 11 Ball ended crank for longitudinal slide adjustment 12 Clamping lever for locking the tailstock sleeve 13 Adjusting nut for locking the tailstock on the guides Ball ended crank for adjusting the tailstock sleeve gt N FK z N LTT TUE y ra E ZA a 27 Cis WABECO n 12 28 Drawing and list of parts Part no Pieces Order no co NOD O BB DON gt I lI cl lI cl cl O O O NA Od BON z O IX AQ PD YY 3s AQ N 10600101 11810005 11810015 10600104 10600105 10600106 11700078 11700030 10600109 10600110 10600111 10600112 11700029 11700030 11810011 10600116 10600117 11820005 11820008 Description Headstock Lubricating nipple Tapered roller bearing Flange Oil wiper ring Main spindle with flange Hexagon socket screw Hexagon nut Transmission axis Transmission lever Axis Shim Washer Hexagon nut Ball bearing Bushing Transmission belt pulley Poly V belt Poly V belt 12 Drawing and list of parts 12 4 Headstock Part no Pieces Order no 20 1 10600120 21 1 10600121 22 1 10600122 23 1 10600123 24 1 10600124 25 3 11810009 26 1 11700053 2
23. eated radially in a bronze bushing 4a and axially in two axial bearings 6 These two axial bearings allow the lead screw to be adjusted free of play 8 If the bearing play needs to be readjusted first of all loosen the outer of the two capstan nuts 7 Then the inner nut is turned against the axial bearing until the lead screw is free of axial play Finally lock the outer capstan nut against the inner nut 13 6 Description of assembly groups 6 4 Tool slides 6 4 1 Transversal slide The front part of the transversal slide rests on a V guide and the rear part on a surface guide The slide is kept on the bed from below by means of the guide rail 28 The hexagon socket screw 74 can be found at the front on the right The clamping piece 76 is clamped to the bottom of the V guide by using this screw This clamping version is suitable for face turning and parting The dovetail guide of the transversal slide is adjustable If readjustment is necessary loosen the hexagon nuts 35 Adjust the threaded pins 59 with the Allen key not too tight so that the slide can easily be moved back and forth by using the ball ended crank 23 Re tighten the hexagon nuts 35 after completion of the adjustment If axial play occurs in spindle 15 please proceed as follows First of all loosen the threaded pin 22 Now the scale support 20 can be turned to the right until there is no more axial play Then re tighten threaded pin 22
24. ft EE i b 4 speed potentiometer main spindle bl rh 12k i punla qs L N ny h L1 p brown p bIPE j yellow green F main switch with low voltage release yellow green blue brow c e Ss O oO c c O O o i O emergency OFF main switch coolant pump coolant im E B brown W Y jh yellow green 46 3 nianu 13 Circuit diagram 13 4 Drive for CNC control This document shows all components of the electrical equipment including the mains connection Z Hr su 55 53 FE lil ili RIN SIS YS t Toi S l 25 55 253 5 gt o 9 o z 5 u LL LL rectifier transformer B80 70 25 77 80VA D x fan O S E 17k 22 Main switch 5 2 o 21 Nsa main switch To change axial direction Z X for CC D exchange green for brown BIBI ALA B A ELT connection clamp circuit board 9 3 55 c T B 2 gt gt 20 D ik main switch 4 2 t c 258 88 9 55 connection clamp axis motor 3 1 3 1 n n Oo o Q Kea gg gt x 5 2 2 7 a x electrolytic Su 2 capacitor 5 63V S 4700 yF o Ci axis motor 47 lt 15 WA BECO 1153
25. g 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 should be cleaned with acidic syndets without abrasive ingredients and rich cream should be applied to regenerate the skin Please also take note of the enclosed information on the general operating instructions 23 24 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 correlation between the level of emission and the level of stress this cannot be used reliably in order to determine whether additional safety measures are necessary or not Other factors which influence the actual stress level of employees are the characteristics of the working area other sources of noise i e the number of machines and other processes going on nearby and so on Apart from that the pe
26. g or the guideways of the slides being destroyed 5 Start up and maintenance Prior to the initial operation the machine must once more be cleaned with great care and all lubrication points have to be lubricated with grease Thoroughly oil the cross support lead screws guiding rods and spindle sleeve Check all spindles by hand in order to ensure they run smoothly Run in the lathe at the lowest speed A full load to start with must be avoided Please pay attention to the following before putting the machine into operation 1 Ensure that the machine is free from protective agent preservative and all sliding surfaces are clean and oiled We recommend the use of petroleum or similar to remove protective agent Lubricate the machine according to the lubricating instructions Release the longitudinal slide clamp and check the slide travel manually for both axes Ensure that the protective hoods are closed Check the condition of the chuck 5 3 Lubrication of the machine The lathe should be lubricated every 8 operating hours according to the lubricating schedule 2 1 og iN Lubricating points bed guide dovetail guide of transversal slide dovetail guide of longitudinal slide and tailstock sleeve are lubricated by using an oil can and a standard lubricating oil moving the slides and the sleeve to and fro while doing so All other lubricating points are to be greased at the designated lubricating nipples with a gre
27. lay 13 6 4 Tool slide 14 6 4 1 Transversal slide 14 6 4 2 Longitudinal slide 14 6 5 Tailstock 15 7 Applications 16 7 1 Longitudinal and transverse turning 16 7 2 Thread cutting and automatic feed 17 7 2 1 Thread cutting 17 7 2 2 Application of change gears 18 7 2 3 Altering the feeds or thread pitches 20 7 2 4 Left hand thread 21 j AN q lt is WWABECO nX 8 Three jaw chuck and four jaw chuck 22 9 Collet chuck 22 10 Lubrication coolant unit 23 11 Declaration of noise levels 24 12 Drawing and list of parts 25 12 4 Diagram for reading the rotational speed 25 12 2 Lubricating plan 26 12 3 Operating elements 27 12 4 Headstock 28 12 5 Bed with lead screw drive 29 12 6 Bed with lead screw drive for ball screw 32 12 7 Tool slide 34 12 8 Lower part of tool slide for ball screw 36 12 9 Tailstock 38 12 10 Drive high speed with 2 0 kW motor 40 12 11 CNC drive X axis 42 12 12 CNC drive Z axis 43 13 Circuit diagram 44 13 1 Motor 1 4 kW 44 13 2 High speed motor 2 0 kW 45 13 3 Motor 1 4 kW with safety cabin 46 13 3 1 High speed motor 2 0 kW with safety cabin 47 13 4 Drive for CNC control 48 lt is WABECO n EC Conformity Declaration Version 07 2010 In the name of the manufacturer Walter Blombach GmbH Tool and Machine Factory based in Remscheid and Neuerburg D 42871 Remscheid Postfach 12 01 61 Phone 0049 2191 597 0 Fax 0049 2191 597 40 D 54673 Neuerburg WABECO Str 1 10 Phone 0049 6564 9697 0 Fax 0049 6
28. ng pieces are to be supported by the tailstock or a fixed stay Apply coolant and lubricant for better surface quality finish and dimensional accuracy Fix processing tools and work pieces on clean clamping surfaces Grease the machine sufficiently Use the correct tools for removing material from the work pieces Set correct bearing clearances and align guides 4 Safety instructions The feed line for the motor must be connected to a sealed contact socket or junction box Have the socket or junction box checked by an electrician beforehand protection against children 2 The socket or junction box must be close enough to the equipment so that the live cable is subject to no stress whatsoever 3 When maintenance or cleaning work is done the machine must be shutdown and the mains plug pulled 4 Donot slow down work pieces or chucks by hand or any other objects 5 Wear safety goggles when working with 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 of the drive closed 8 The turning tools must be tightly clamped at the correct height and as short as possible 9 The turning tools must never be replaced when the machine is running 10 Never leave the clamping chuck key in even when not in operation 11 Always pay attention to the clamping width of the lathe chuck lathe chucks 2 max 40mm drill chucks max 100mm 2 1
29. ng range The clamping force would be insufficient and the jaws may detach themselves Mounting of turning jaws The jaws and guides are numbered from 1 3 resp 1 4 Open the chuck by means of the chuck key until the jaws loosen order 3 2 1 resp 4 3 2 1 Now take the jaws beginning with number 1 and insert it into guide number 1 Push the jaw number 1 towards the chuck centre 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 inserted in the guide provided The same now happens to number 2 Proceed with number 3 and number 4 in the same way Subsequently examine the positions of the jaws Mounting of drilling jaws If you wish to work with drilling jaws afterwards the process repeats itself in the same order first jaw 1 then 2 then 3 then 4 9 Collet chuck 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 work spindle 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 lifted from the concentric flange of the work spindle and the closer can be inserted into the work spindle by gently pushing it Subsequently insert the required collet chuck into the closer and by means of the hand draw in tube whi
30. of parts 12 12 CNC drive Z axis Part Pieces Order no Description no 32 1 10600801 Belt pulley Z30 for ball screw 32 1 1 106008011 Belt pulley 224 for trapezoid 33 1 11700087 Pin 34 1 10600802 Motor plate 35 2 11700040 Cylinder screw 37 1 10600803 Motor housing 38 1 11800003 Stepper motor 39 4 11700088 Washer 40 4 11700039 Cylinder screw 41 4 11700050 Hexagon nut 42 1 10800804 Cap for motor housing 43 4 11700107 Cylinder screw 44 1 1121021213 Belt pulley 212 45 1 11700049 Cylinder pin 46 2 1121021212 Washer for toothed wheel Z12 47 2 11700048 Locking pin 48 1 11820006 Toothed belt 49 1 10800805 Protective cover 50 2 11700019 Nut 42 eun 13 Circuit diagram 13 1 Motor 1 4 kW This document shows all components of the electrical equipment including the mains connection mains plug emergency OFF switch main switch reversing switch l Ed s lad C Tas ek e limit E switch protective control electronics SERIE AT HTE mi 43 13 Circuit diagram 13 2 High speed motor 2 0 kW This document shows all components of the electrical equipment including the mains connection Connection box high speed motor Gnd p 1 te APAN 2 iu iN white 5 reversing switch 2 blue i R L Li LoT 5 3 brown B5 pink potentiometer AN In p15 p green AN Gnd 16 emergency OFF switch M blue2 pen
31. olt A and between A and C Proceed as described under pos 1 f g Changing the feed from 0 085 mm to thread pitch 12Z 1 Proceed exactly as already described The procedure differs merely in additionally replacing toothed belt pulley Z48 on bolt A by toothed belt pulley Z34 The feed is switched over via the T handle on the front side of the apron When cutting threads please make sure that the feed remains permanently switched on so that the turning tool returns to its home position if more than one cutting procedure is required After completion of the cutting procedure the transversal slide disengages the tool and travels back to its home position when changing the sense of rotation of the motor by operating the reversing switch 20 T Applications 7 2 4 Left hand thread To cut an LH thread just mesh the right hand intermediate gear on the quadrant with the drive wheel on the main spindle Figure 9 4 shows the condition for left hand thread cutting In order to pivot the tumbler gear all you have to do is loosen the clamping screw tumbler gear clamping screw 21 8 Three jaw chuck and four jaw chuck The three jaw chuck serves for clamping circular triangular and hexagonal work pieces centrically to the spindle axis The four jaw chuck serves for clamping square work pieces centrically to the spindle axis Danger of accident Do not try to clamp workpieces exceeding the allowable clampi
32. oothed belt wheel 69 3 10600224 Disc 70 3 11700053 Hexagon nut 71 3 11810009 Lubricating nipples 72 1 11820003 Toothed belt 73 1 11820004 Toothed belt 74 1 11820004 Toothed belt 15 1 11810020 Needle bearing 76 1 10600241 Clamping bolt 33 N m pu C0 Q tj O pa o LO C CO O gt o p C Tool slide 12 12 7 12 Drawing and list of parts 12 7 Part no CONDO OF ON ek ek X ES A LX CX B O O 0 ND O BB ON O Pieces Order no ma ma AQ RO N mm c 00 B PNY WB NN CE EN WW a Nc Tool slide 10600301 10600302 10600303 10600304 10600305 10600306 10600307 10600308 11700095 10600310 11840013 11700096 10600313 11700004 10600315 10600316 10600317 11810004 11850002 10600320 10400428 11700087 11840011 11700023 10600325 10600326 11700097 10600328 11700061 11700026 11700024 10600333 11700098 11700019 10600336 10600337 11700081 10600339 11700028 11850005 11700099 10600344 10600345 10600346 10600347 10600348 11700100 11810005 11700100 11840009 11700049 Description Lower part of transv slide Upper part of transv slide Clamping ring Guide ring Longit slide lower part Longit slide upper part Lathe apron Clasp nut Cylindrical pin Clasp holder Switch lever Feather key Washer Hexagon socket screw Spindle cross slide Spindle bear cross slide Scale ring cr
33. oss slide Steel ball Pressure spring Scale holder Thrust piece Threaded pin Ball ended crank Spiral clamping pin Nut Washer Hexagon bolt Guide rail Hexagon bolts Hexagon socket screw Spiral clamping pin Adjustable gib Threaded pin Hexagon nuts Clamping claw Thrust disc Hexagon nut Thread bolt Hexagon bolt Pressure spring Spiral clamping pin Spindle longitudinal slide Spindle bear longit slide Scale ring longit slide Guide piece Support bearing Hexagon socket screw Lubricating nipples Hexagon socket screw Ball ended crank Spiral clamping pin Part no Pieces Order no BR ANMDNRADONNANAN ABBR ABANAANNABBANNNW AAA 11700078 11700101 10600357 11700102 11700029 11700103 11700030 11840014 11700026 11700104 10600368 11810011 11810011 10600371 10600372 11700033 11700037 11700022 10600376 10600377 10600378 11700026 10600380 11700078 10600382 10600383 11700026 11700031 10600388 10600390 10600391 11700087 11700019 Description Hexagon socket screw Hexagon screw Adjustable gib Threaded pin Washer Hexagon screw Hexagon nut Handwheel Hexagon socket screw Feather key Scale support Ball bearing Ball bearing Scale ring Pinion Hexagon socket screw Hexagon socket screw Hexagon socket screw Clamping piece Intermediate gear Washer Hexagon socket screw Guide rails Hexagon socket screw Felt Felt clamp Hexagon socket screw Hexagon socket screw Felt
34. rmitted stress levels may vary from country to country This information is to allow the user of the machine to assess the dangers and risks more accurately Noise levels in accordance with DIN 45635 part 1 noise level in work area idle phase LpA 63 dB A load phase LpA 67 dB A 12 12 1 Drawing and list of parts Diagram for reading the rotational speed V m min 4000 3000 2000 1000 800 600 400 Hie AA 4 2500 1600 1250 PAPAA PAF WW A WILL l Mui Table 1 4 kW motor 0 10 20 30 40 50 60 70 80 90 100 30 35 50 90 150 200 290 350 400 460 490 AWA 80 100 160 200 BEE EEE e en EG AN Dm m en en BG AN on ee 25 12 Drawing and list of parts 12 2 Lubricating plan aai FY 1 E m r mr Te E 1 CA EEE aa SY ou tre avem Ja PM WAWY 1 BN M DADA ON ss G C 1 Every 8 operation hours A Every 8 operation hours 26 12 Drawing and list of parts 12 3 Operating elements Potentiometer rotary knob for the speed regulation of the electric drive motor Emergency OFF switch Reversing switch for changing the turning direction main spindle Main switch with undervoltage release Opening and closing of clasp nut Retention screws for longitudinal sli
35. t 12 6 Description of assembly groups 6 2 6 Tumbler gear adjustment As shown in the diagram chapter 2 2 the left hand wheel on the tumbler gear engages with the toothed wheel of the main spindle This setting is required for right hand threads or normal feed i e if the spindle is turning in anti clockwise direction looking at the chuck the tool slide will move towards the chuck After loosening the clamping bolt 50 the tumbler gear can be pivoted over to the left so that the right hand intermediate wheel engages in the toothed wheel of the main spindle This setting serves for cutting left hand threads or the slide moves away from the chuck towards the tailstock see chapter 2 4 while the sense of rotation the main spindle stays the same 6 2 7 Protective cover for chuck The main spindle of the machine will only run with the chuck protective hood 24 closed For safety reasons it is not possible to switch the machine on if the protective hood is open 6 3 Bed with lead screw drive 6 3 1 Overload clutch In order to avoid damage to the drive system of the lead screw an overload clutch is fitted on the lead screw drive side The clutch becomes effective when the machine is overloaded and also when the machine hits an end stop in longitudinal direction The clutch is adjusted with the hexagon nuts 45 and counter screwed 6 3 2 Setting the bearing play of the lead screw On the right hand side the lead screw is s
36. t one second so that the relay on the controller board has enough time to switch over Before connecting the machine to the mains supply the earthing has to be checked 6 2 3 Speed regulation for 1 4 kW motor The rotational speed of the work spindle can be adjusted infinitely variable from 380 2300 min 1 by means of the potentiometer located at the front of the machine Should you require the lower rotation level with a minimum speed of 30 min 1 the drive belt must be relocated Proceed as follows see headstock After removing the protective cover release the driving belt For this release the nut 14 and loosen the screw 51 as far as is necessary to put the drive belt on the other gear ratio 39 and 17 easily For tensioning the belt tighten the screw as firmly that the belts cannot slip from the pulleys Finally re tighten the nut 14 Speed regulation for 2 0 kW motor The rotational speed of the work spindle can be adjusted infinitely variable from 0 5000 min 1 by means of the potentiometer located at the front of the machine 6 2 5 Speed transmission from main spindle to lead screw The toothed wheel 37 on the main spindle drives the two intermediate gears 47 on the tumbler gear On the centre of motion of the tumbler gear there is a toothed wheel with a toothed belt wheel The toothed wheel is driven by the intermediate gears and the toothed belt wheel assumes the drive of the gear combinations on the quadran
37. ve can be moved axially by the crank 21 to be found at the rear end via the threaded spindle 5 Applications ar 7 1 Longitudinal and transverse turning Longitudinal turning In the case of longitudinal turning the tool moves parallel to the axis of the work piece For longitudinal rough turning it is recommended to use either a straight or an arcuated turning tool Transverse turning The machining 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 cross support is to be locked The main cutting lip of the turning tool must be exactly centred so that no lug remains in the work piece centre The arcuated tool is used for transverse turning to 1 2 to 3 to 4 to 5 to 6 16 HA TOH MI Roughing tools arcuated to the left and or to the right By using them a maximum of material is removed 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 and transverse turning Offset side turning tool Used for finishing smooth surface in the case of longitudinal and transverse turning Outside thread turning tool Used for cutting outside threads Parting tool Used for the cutting of grooves and slicing of Work pieces When inserting the parting tool No 5 pay careful attention to the exa
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