WABECO D2000E, Operating Instructions Manual

Page 1: ...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 www wabeco remscheid de ...

Page 2: ...D2400 E 22 3 2 Circuit diagram for D3000 E 23 4 Delivery and installation 24 5 Starting up and maintenance 25 6 Overload protection 25 7 Safety devices and recommendations 26 8 Startup and Maintenance 27 8 1 Electrical equipment 27 8 2 Startup 27 8 3 Maintenance 28 8 4 Lubrication 29 8 5 Initial cleaning of the machine 29 8 6 Spindle head 30 8 7 Compound rest 31 8 8 Tailstock 29 9 Speed regulation...

Page 3: ...nd thread 40 12 Angle plate with milling table 41 13 Three jaw chuck and four jaw chuck 42 14 Tool holder with conical sleeve 42 15 Steady and follow rest 43 16 Square turret head 43 17 Hand tool rest for turning wood 44 18 Wood turning lathe centre 44 19 Unit for lubrication coolant 45 20 Declaration of noise levels in accordance with DIN EN 24871 46 German Industrial Standard 21 Disposal of the ...

Page 4: ...illing and drilling machines specified below Universal Lathes Typ D2000E D2400 E D3000 E meet the following regulation requirements for standard serie production EC directive for machines EWG 91 68 and 89 392 EC low voltage directive 73 23 EWG In order to meet implement the requirements of the above mentioned directives the following applicable and previously published standards have been adhered ...

Page 5: ... 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 Wir können Ihnen wahlweise unsere Bedienungsanleitungen und Prospekte in englischer und französischer Sprache kostenlos zusenden We are able to send you free of charge our Operating Instructions and leaflets...

Page 6: ...0 mm Guideways Longitudinal support ground guiding bars Cross support adjustable dovetail guide Stripping rings protection of the guides Length of guides 575 mm Width of guides 130 mm diameter of chuck work measured above the guiding bars 220 mm Tail stock Tail spindle s range of displacement 65 mm Tail spindle s hole bore cone2 lateral displacement of the tailstock to both sides 10 mm Advance Aut...

Page 7: ...ht of turning tools max 20 mm Guideways Longitudinal support ground guiding bars Cross support adjustable dovetail guide Stripping rings protection of the guides Length of guides 740 mm Width of guides 130 mm Ø of guides 30 mm diameter of chuck work measured above the guiding bars 220 mm Tailstock Tail spindle s range of displacement 65 mm Tail spindle s hole bore cone2 lateral displacement of the...

Page 8: ...the upper slide rest 360 Height of turning tools max 20 mm Guideways Longitudinal support ground guiding bars Cross support adjustable dovetail guide Stripping rings protection of the guides Length of guides 740 mm Width of guides 130 mm Ø of guides 30 mm diameter of chuck work measured above the guiding bars 220 mm Tailstock Tail spindle s range of displacement 65 mm Tail spindle s hole bore cone...

Page 9: ...6 10201116 Tapered roller bearing 11141 10211141 Starter pulley 1114 10201114 Toothed belt pulley 1113 10201113 Spacer sleeve 1112 10101112 Belt pulley for Universal Lathe D2000 1112 10201112 Belt pulley for Universal Lathe D2400 E 1111 10201111 Regulating nut 128 10200128 Plexiglass cover 1281 10201281 Adjusting ring 1282 10201282 Shaft 1283 10201283 Eccentric 1284 10201284 Stop 1285 10201285 Bra...

Page 10: ...1251 10201251 Stud bolt radial nut 1252 10201252 Support 1253 10201253 Potentiometer 1254 10201254 Master switch with undervoltage release 1255 10201255 Switch right left 1256 10201256 Motor 1260 10201260 Limit switch protective cover 1258 10201258 Circuit board 1257 10201257 Motor cover 1259 10201259 Screws 10201200 Collecting reservoir for chips ...

Page 11: ...11 2 Drawings and list of parts 2 2 Support with motor and protective cover for D2400 E and D3000 E ...

Page 12: ...justing ring 1126 10201126 Pressure spring 1127 10201127 Coupling 1131 10201131 Eccentric shaft complete 11311 10211311 Stud bolt nut 11315 10211315 Ball bearing 114 10200114 Change gear quadrant 1141 10201141 Hexagon bolt 11411 10211411 Bronze bushing 11215 10211215 Nut 114114 102114114 Toothed belt pulley Z 14 1142 10201142 Washer 1143 10201143 Washer 114816 102114816 Change gear Z16 without pic...

Page 13: ...13 2 Drawings and list of parts 2 3 Leading spindle drive for D2000 E and D2400 E ...

Page 14: ...5 3 screws 6 10300006 Bracket 7 10300007 2 scres 8 10300008 2 adjusting nuts 9 10300009 Pressure ring 10 10300010 Bushing 11 10300011 2 thrust bearing 12 10300012 Run on ring 13 10300013 2 screws 14 10300014 Needle bearing 15 10300015 Distance ring 16 10300016 Needle bearing 17 10300017 Toothed belt pulley 18 10300018 Clutch disk 19 10300019 Handle 20 10300020 Operating pin 21 10300021 Threadcutti...

Page 15: ...15 2 Drawings and list of parts 2 4 Leading spindle drive for D3000 E 1 2 3 4 5 7 6 21 20 19 18 17 16 15 14 13 12 11 10 9 8 ...

Page 16: ...w 11471 10111471 Washer 114114 102114114 Toothed belt pulley Z 14 11823 10111823 Toothed belt 11914 10111914 Drive belt J 610 11911 10111911 Screw with washer 1173 10101173 Bearing plate 11811 10111811 Nut and washer 11712 10111712 Adjusting rod 1171 10101171 Axle 1128 10101128 Ball bearing 11722 10111722 Roller 11721 10111721 Retaining ring 1181 10101181 Axle 11824 10111824 Retaining ring 11822 1...

Page 17: ...17 2 Drawings and list of parts 2 5 Leading spindle drive with gear motor for D2000 E ...

Page 18: ...ib 321 10200321 Lower part of turning carriage 322 10200322 Upper part of turning carriage 3221 10203221 Spindle bearing compl with graduated ring 32211 10232211 Spindle for turning carriage 32212 10232212 Ball ended crank 3222 10203222 Readjusting gib 3223 10203223 Stud bolt 32231 10232231 Clamping plate 32232 10232232 Hexagon bolt 32233 10232233 Pressure spring 32234 10232234 Thick nut 10200300 ...

Page 19: ...19 2 Drawings and list of parts 2 6 Cross table ...

Page 20: ...ailstock 421 10200421 Quill 422 10200422 Flange 1151 10201151 Hexagon socket screw 423 10200423 Spindle 4231 10204231 Adjusting ring 4234 10204234 Spring washer 4233 10204233 Washer 31212 10231212 Ball ended crank 424 10200424 Hexagon bolt with washer 4251 10204251 Capstan with clamping bolt 42511 10242511 Insert 4141 10204141 Insert 4252 10204252 Feather key 119 10200119 Lubricating nipple 102004...

Page 21: ...asher 523 10200523 Axial needle bearing 31212 10231212 Ball ended crank 4231 102H4231 Spacer sleeve 524 10200524 Bronze bushing 53 10200053 Protective channel 531 10200531 Screw washer 4232 10204232 Graduated ring 4233 10204233 Retaining ring 533 10200533 Lubricating ring 541 10200541 Hexagon bolt 542 10200542 Washer 543 10200543 Serrated lock washer 544 10200544 Hexagon nut 10200500 Rear bearing ...

Page 22: ...22 3 Block circuit diagram 3 1 for D2000 E and D2400 E mains plug emergency OFF main switch reversing switch switch for protection cap potentiometer Date Danger control electronics motor ...

Page 23: ...am 3 2 for D3000 E potentiometer capacitor rectifier transformer reversing switch main switch emergency OFF mains plug potentiometer control electronics motor feed motor control electronics reversing Switch for Protection cap ...

Page 24: ...eight of the machine without warping see technical data and check with spirit level and has an even surface a steel plate The lathe must be firmly screwed down onto the base To facilitate this there are 9 mm holes in the machine base Good results and a minimum of vibration during operation can only be guaranteed if the above mentioned requirements for secure mounting have been kept to The installa...

Page 25: ...h and dimensional accuracy Fix processing tools and workpieces on clean clamping surfaces Grease the machine sufficiently Use the correct tools for removing the material from the workpieces Set correct bearing clearances and align guides early enough 6 Overload protection i Wait approx 1 second after switching off the machine manually or after an automatic switchdown following an overload before y...

Page 26: ... The turning tools must never be exchanged when the machine is running 10 Never leave the clamping chuck key in even when not in operation 11 Observe the bearing distance of the turning chuck Turning jaws max 40mm Drilling jaws max 100mm 12 Never take measurements on work pieces being turned danger of accidents and damage to the measuring gauges 13 Do not wear loose items of clothing ties shirt sl...

Page 27: ...ine must once more be cleaned with great care All lubricating points have to be furnished with grease while the cross slide the threaded spindles the guide bars and the quill are thoroughly oiled Turn by hand all spindles in order to check for their smooth turning Run in the lathe with the lowest possible rotary speed being switched on A full load to start with must be avoided 8 3 Maintenance The ...

Page 28: ...ccessible from below the feed rod as well as the tailstock quill have to be greased at intervals of 100 service tours each using lubricating oil When greasing make sure to put the slide of the cross slide to its hindmost position while extending the tailstock quill to its foremost posision Greasing the tailstock spindle is performed via the hollow borehole within the quill RUECKW VORW 0 AUS NOT ap...

Page 29: ... OFF lever for automatic feed Should a readjustment of the bearings be neccessary 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 a clockwise direction until the bearings again run free of play the work spindle being easily able to be turned by hand 3 Tighten the l...

Page 30: ...nsverse slide rest and can be pivoted through 360 degrees Thus it is suitable for the turning of tapers For adjustment the 4 mm Allen key is used to loosen the two screws located on the outer sides of the transverse slide rest The arrow on the transverse slide rest There is a scale of the degrees on the longitudinal slide rest The distance between two graduation marks represents one degree Scale r...

Page 31: ...urning operation establish whether the working piece is cylindrical and if necessary correct the position of the tailstock Solid tailstock sleeve The solid tailstock sleeve which is provided with a millimetre scale is designed in such a way that the lathe centre drill barrel or chuck are automatically ejected when turning back Tool clamping An inner cone MT 2 which is worked into the tailstock sle...

Page 32: ...m is to be turned with a cutting speed of 100 m min Now from those speeds available the one is selected which is nearest to the ideal speed of 1592 1 min in our case 1600 1 min 9 1 1 Speed Setting for Working with Aluminium workpiece Ø approx r p m cutting speed m min 10 mm 2300 75 20 mm 1600 100 40 mm 800 100 60 mm 530 100 80 mm 400 100 100 mm 320 100 9 1 2 Speed setting for working with steel wo...

Page 33: ... the machine speed setting at the potentiometer 1 step r p m 2 step r p m 10 45 200 20 105 350 30 175 740 40 260 1050 50 325 1440 60 360 1650 70 400 1860 80 460 2120 90 490 2160 100 500 2300 Rotational speed 45 400 rpm The drive belt must be relocated if the lower speed stage with a minimum speed of 45 rpm is required Proceed as follows Remove the protective cover and release the drive belt by uns...

Page 34: ...aterial is to be cut off in as short a time as possible without paying attention to the finish on the surface of the work piece They can be used for longitudinal and transverse turning to 3 Offset side turning tool Used for smoothing clean surface in the case of longitudinal and transverse turning to 4 Outside thread turning tool Used for cutting of outside threads to 5 Narrow square nose cutting ...

Page 35: ...as otherwise the profile of the thread would be distorted In order to obrain the correct position of the flanks of the thread to the axis of the workpiece the grinding jig is put against the work piece and the turning tool is adjusted in accordance with it diagram 1 For this purpose the jig is pushed successively on to both flanks of the turning tool The feed of the thread turning tool is effected...

Page 36: ...d in order to prevent the work piece from being pushed away Overload clutch To avoid damage at the advance system the main spindle and the leading spindle drive are connected with an overload clutch 10 2 2 Application of change gears optional for D2000 and D2400 E For the purpose of automatic longitudinal turning there are two feed rates being at your disposal 0 085 mm and 0 16 mm revolution Upon ...

Page 37: ...ng the main spindle with A by placing the toothed belt onto the great driving pulley E d Remove both tooth belt pulleys Z 14 from their bolts A and B and change them for tooth belt pulley Z 18 or tooth belt pulley Z 20 respectively Then tighten bolt A Mount and tighten the washers and nuts of A and B e Mount bolt B together with both tooth belt pulleys into the change gear quadrant again by slight...

Page 38: ...6 Put on toothed belt connecting the main spindle with bolt A and from A to C f g Proceed as described under pos 1 f g Z 14 bolt B escape Z 48 Z 48 C Z 48 i Only the two short toothed belts 1145 are required for cutting metric threads The slightely longer toothed belt 1146 which connects the main spindle with wheel A The toothed belt 1145 connects wheel B with wheel C 3 Changing the feed from 0 08...

Page 39: ... 22 During cutting of inch thread this wheel has to be replaced through the tooth wheel Z 34 For the different thread pitches only the tooth wheels B beside Z 48 and C on the main spindle according to picture 6 22 have to been changed b Select slowest spindle feed c Turn the handle 19 on the symbol thread turning The handle must be in function till the thread is ready produced For the cutting of s...

Page 40: ...workspindle Loosen the adjustment nut and remove from the workspindle f Remove the V belt pulley No 1112 the separator bush No 1113 and the toothed belt gear No 1114 from the workspindle Mount the toothed belt from the workspindle and tighten firmly with the adjustment nut g Mount toothed gear Z 75 and the toothed belt pulley No 114114 on to the bolt A and tighten with the washer and the hexagon n...

Page 41: ...serted into the T groove of the clamping plate In addition a machine vice can be attached to the clamping plate The tool is to be clamped as short as possible in the collet chuck danger of breaking If the tool is firmly clamped the depth adjustment can be made over the feed shaft Assembly of the angle plate with the milling table At first you remove the longitudinal slide rest from the transversal...

Page 42: ...sverse spiral has taken hold of number 1 number 2 must be put in the guide provided The same now happens to number 2 as to number 1 Proceed with number 3 and number 4 in the same way Subsequently examine the position of the jaws Mounting of drilling jaws If afterwards you again want to work with outer jaws the process repeats itself in the same order first jaw 1 then 2 then 3 then 4 14 Collet chuc...

Page 43: ...w rest The follow rest is used particularly for turning thin long shafts and for turning threaded spindles It is screwed firmly on to the threaded drilled holes of the compound rest provided for this purpose so that it holds the workpiece as near as possible to the turning tool 16 Square turret head The square turret head is used instead of the clamping plate in order to clamp the tools Four turni...

Page 44: ... To avoid accidents the hand tool rest is to be pushed as near as possible to the workpiece and readjusted in the course of machining 18 Wood turning lathe centre The wood turning centre serves to accept workpieces out of wood between the centres and enables a machining of the piece throughout its entire length without any reclamping being necessary It is contained in the inner taper of the worksp...

Page 45: ...ike to recommend as follows 1 Use concentrated products free of nitrates 2 Use concentrates without secondary amins 3 Use products with the lowest possible allergy potential 4 When mixing a refill of lubrication coolant please observe the following clean rinse the circulation system tray filter determine the concentration necessary to meet the technical demands concentrate water 1 5 1 30 check the...

Page 46: ...vels may vary from country to country This information is to allow the user of the machine to assess the dangers and risks more accurately 21 Disposal of the lathe The transport and protective packaging made up of the following materials corrugated cardboard polystyrene free of freon polyethelene foil non returnable wooded pallet untreated Euro pallet deposit If you have no further need of these a...