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Status at 06/2018 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.
Index Declaration of conformity for D2000 Declaration of conformity for D2400 Declaration of conformity for D3000 Important safety notes Intended use Improper and incorrect use 1.3 Modifications to the machine Safety regulations for proper use 1.5 Safety features Explanations of the symbols Delivery and set up...
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Index Re-adjusting the tool slide Tailstock 3- and 4-jaw lathe chuck Operational faults and the elimination of such Control elements 14.1 D2000 and D2400 lathes 14.2 D3000 lathe Drawings and legends 15.1 Headstock 15.2 Foundation with motor and cover cap for D2000/D2400 15.3 Foundation with motor and cover cap for D3000 15.4 Change gear quadrant for D2000/D2400/D3000 15.5 Transmission and lead screw drive for D2000/D2400/D3000 15.6...
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Index Fixed stay 19.1 Operating the fixed stay 19.2 Drawing and legend Live stay 20.1 Operating the live stay 20.2 Drawing and legend Clamping angle with milling attachment (optional) 21.1 Mounting the clamping angle with milling attachment to the lathe 21.2 Control elements 21.3 Feed motion of the milling attachment 21.4 Adjustment of the dovetail guide 21.5 Alignment of the milling attachment 21.6 Lubrication of the clamping angle with milling attachment 21.7...
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Walter Blombach GmbH Werkzeug- und Maschinenfabrik with headquarters in Remscheid and Neuerburg D-42871 Remscheid Postfach 12 01 61 Telefon: (02191) 597-0 Fax: (02191) 597-42 D-54673 Neuerburg WABECO Str. 1-10 Telefon: (06564) 9697-0 Fax: (06564) 9697-25 that the following named Universal lathe Type: D2000 in the serial version, meets the following relevant regulations - Machinery Directive 2006/42 EG...
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Walter Blombach GmbH Werkzeug- und Maschinenfabrik with headquarters in Remscheid and Neuerburg D-42871 Remscheid Postfach 12 01 61 Telefon: (02191) 597-0 Fax: (02191) 597-42 D-54673 Neuerburg WABECO Str. 1-10 Telefon: (06564) 9697-0 Fax: (06564) 9697-25 that the following named Universal lathe Type: D2400 in the serial version, meets the following relevant regulations - Machinery Directive 2006/42 EG...
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Walter Blombach GmbH Werkzeug- und Maschinenfabrik with headquarters in Remscheid and Neuerburg D-42871 Remscheid Postfach 12 01 61 Telefon: (02191) 597-0 Fax: (02191) 597-42 D-54673 Neuerburg WABECO Str. 1-10 Telefon: (06564) 9697-0 Fax: (06564) 9697-25 that the following named Universal lathe Type: D3000 in the serial version, meets the following relevant regulations - Machinery Directive 2006/42 EG...
Important safety notes Intended use The lathes described in these operating instructions are designed for the processing of metal, plastic and timber only. To ensure safe operation of the lathes, the regulations set out in the chapter: „Safety regulations“ must be observed.
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Important safety notes Safety regulations for proper use Only specially trained persons may operate the machine. The guarantee and warranty are voided if damages are caused by improper operation. We remind you that no liability will be accepted for damages caused by not observing these operating instructions.
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Important safety notes Safety regulations for proper use O nly 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. P rotect the machine from damp. 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.
Important safety notes Safety features In order to enable you to work safely with our machines, we have incorporated the following safety mechanisms. These meet the relevant European safety requirements. ■ Chuck protection hood The main spindle of the machine operates only with the chuck protection hood closed. For safety reasons, if the chuck protection hood is open, the machine cannot be switched on.
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.
Delivery and set up Transporting the machine We recommend two people to lift the machine, using the positions shown (1). To do this, a sufficiently dimensioned, at least Ø 20 mm steel rod is pushed through the main spindle. The machine should be carried and balanced by one person at the steel rod and by the other person, at the shown position on the opposite underside of the bed.
Identification of the model The precise model designation of your machine can be found on the type plate attached to the machine. D2000 4.2.1 Declaration of noise levels Declaration of noise levels in accordance with DIN EN ISO 3744 Emission values in idle...
Specifications regarding the machine D2000 4.2.2 Technical data Working range Center distance 350 mm Center height 110 mm Turning Ø above cross slide 126 mm Turning Ø above the guideways 220 mm Main drive motor Nominal voltage 230 V Nominal frequency 50/60 Hz Nominal performance of the spindle motor 1.4 kW...
Specifications regarding the machine D2000 4.2.3 Dimensions D2400 4.3.1 Declaration of noise levels Declaration of noise levels in accordance with DIN EN ISO 3744 Emission values in idle Emission sound pressure level at the workplace at 50 % = 60.8 dB (A at 100 % = 72.0 dB (A)
Specifications regarding the machine D2400 4.3.2 Technical data Working range Center distance 500 mm Center height 110 mm Turning Ø above cross slide 126 mm Turning Ø above the guideways 220 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...
Specifications regarding the machine D2400 4.3.3 Dimensions D3000 4.4.1 Declaration of noise levels Declaration of noise levels in accordance with DIN EN ISO 3744 Emission values in idle Emission sound pressure level at the workplace at 50 % = 60.8 dB (A at 100 % = 72.0 dB (A) Sound power level at 50 %...
Specifications regarding the machine D3000 4.4.2 Technical data Working range Center distance 500 mm Center height 110 mm Turning Ø above cross slide 126 mm Turning Ø above the guideways 220 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...
Specifications regarding the machine D3000 4.4.3 Dimensions Revolution selection Select the spindle revolutions according to the material type of workpiece diameter: ⇒ Small workpiece diameter Relatively high revolutions ⇒ Large workpiece 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: Revolutions (n) = Cutting speed (V) x 1000 Workpiece diameter (d) x 3.14...
Specifications regarding the machine Diagram for reading off the revolutions 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.
Specifications regarding the machine Revolution changer Setting on the potentiometer 1st setting rpm 2nd setting rpm 1050 1440 1650 1860 2120 2160 100% 2300 Electrical equipment The main drive motor (single phase series-wound motor) is supplied already installed. ■ The main spindle drive has an ON/OFF switch with under-voltage trigger. ■ In order for the machine to start, the turn switch for forwards-reverse must be set to the required direction of rotation. ■ Then switch on at the ON/OFF switch. ■ The ON/OFF switch must also be switched on again after the power is interrupted. ■ To 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.
Achieving optimum results and avoiding incorrect usage ■ Use of suitable processing tools. ■ Adaptation of revolution setting and feed to the material, workpiece and tool. ■ Tension tools as far into the tool holder as possible (short projecting length). ■...
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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 workpiece).
(Figure 1). To do this, push the gauge up to both flanks of the turning steel, one after another. Figure 1: Setting the thread turning steel Change gears (optional for lathes D2000 and D2400) ■ The change gears belonging to the accessories create the connection between the feed drives and the lead screw.
Thread cutting and automatic feed Use of change gears For automatic longitudinal turning, there are two feeds available with 0.085 and 0.16 mm per revolution (the wheels are set at the factory for feed with 0.085 mm per revolution). Fitting various toothed wheel combinations enables metric thread cutting from 0.25-6 mm and inch threads with gradients of 10Z/1“-36Z/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.
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Thread cutting and automatic feed Use of change gears Z/1“ Z/1“...
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Thread cutting and automatic feed Use of change gears Table for thread cutting for very fine threads with a second change-gear stud 0.12 0.22 0.24 0.25 0.30 Table for automatic longitudinal feed mm/σ 0.085 0.16...
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Thread cutting and automatic feed Use of change gears Working with the automatic longitudinal feed 1. Turn the control lever upon the longitudinal turning symbol. Turn the lead screw by use of the ball crank, in order to ensure the lock of the clutch disk. 2.
Thread cutting and automatic feed Left-hand thread (optional) In order to cut left-hand thread the toothed belt wheel on top of bolt (F) is to be interchanged with the toothed wheel Z 75 and the toothed belt wheel (B) on top of the main spindle is to be interchanged with the toothed belt wheel Z 50. ■ Pull the main plug, loosen the lock screw on top of the cover cap and afterwards open the cover cap. ■ Loosen the drive belt (K) (v. revolution changer) and remove it from the main spindle. ■ Undo the lock screw (D) of the quadrant. Undo slightly the bolts (F) and (H) on the quadrant and remove the toothed belt (E) and (G) ■ In order to be able to demount the toothed belt wheel the bolt (F) needs to be moved upwards and the bolt (H) downwards.
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. ■...
Lubrication of the machine All other lubrication points are lubricated with a grease press at the designated lubrication nipples. Lubricate prior to any use with grease vor jedem Gebrauch mit Maschinenöl schmieren Lubricate prior to any use with grease Re-adjusting the main spindle The headstock is screwed to the lathe bed. The headstock contains the main spindle with two adjustable precision tapered roller bearings.
Re-adjusting the tool slide The tool slide consists of the longitudinal- and cross slide. The corresponding dovetail guides are adjustable constructed. If adjustment is required, please proceed as follows: 1. Undo counter nuts. 2. Using a pin wrench tighten the regulating screw in such a way that the skid is still able to move easily.
Tailstock ■ The tailstock can be moved on the guide rods. ■ By moving the clamping lever (5), the tailstock can easily be secured in any position. ■ The tailstock is made up of an upper and lower section. ■ The top part can be moved 10 mm to both sides by undoing the hexagon screw (6) and is therefore usable for lathe slim cones.
3- and 4-jaw lathe chuck The 3-jaw lathe chuck Is used to tension circular, three and six edged workpiece centrally to the spindle axis. The 4-jaw lathe chuck Is used to tension square workpieces centrally to the spindle axis. Risk of accidents ■...
Operational faults and the elimination of such Operational faults Possible cause Remedy Machine cannot be 230V voltage is not present Plug is not fitted correctly switched on Check the fuse for the socket The chuck protection hood is Close the chuck protection not closed hood Emergency off switch not Unlock the emergency off unlocked switch Direction of rotation has not...
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Operational faults and the elimination of such Operational faults Possible cause Remedy Transverse or longitudinal slide Guide play is set too narrowly Adapt the guide play cannot be moved or can only be moved with considerable force Rust on workpieces of Wrong coolant set Check the mixing ratio of the machine parts when using...
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Operational faults and the elimination of such Operational faults Possible cause Remedy Tool overheated Revolutions too high Reduce the revolutions Feed too high Reduce the feed Working without coolant Use coolant Insufficient coolant feed at Align the coolant hose correctly the cutting edge Tool blunt Sharpen tool or use a new tool Increased friction caused...
Control elements 14.1 D2000 and D2400 lathes VORW RUECKW 1. Safety screw for the drive protection hood 2. Switch lever for the automatic along feed 3. Chuck protection hood 4. Holding screw for longitudinal slide 5. Tensioning nut for tool clamping plate 6. Ball crank for adjusting the longitudinal slide 7. Clamping screw for clamping the tool slide...
Control elements 14.2 D3000 lathe VORW RUECKW 1. Safety screw for the drive protection hood 2. Switch lever for the automatic along feed 3. Chuck protection hood 4. Holding screw for longitudinal slide 5. Tensioning nut for tool clamping plate 6. Ball crank for adjusting the longitudinal slide 7. Clamping screw for clamping the tool slide 8.
Drawings and legends 15.2 Foundation with motor and cover cap for D2000/D2400...
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Drawings and legends 15.2 Foundation with motor and cover cap for D2000/D2400 Part No. Items Order No. Description 16173800006012 Safety screw 51400206-0001 Cover hood 51004015-0001 Stud bolt 51500606 On-Off switch 51500807-0001 Potentiometer complete 51500608 Turn switch 51500624-0001 Emergency off switch complete 51500102-0002...
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Drawings and legends 15.3 Foundation with motor and cover hood for D3000...
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Drawings and legends 15.3 Foundation with motor and cover hood for D3000 Part No. Items Order No. Description 16173800006012 Safety screw 51400302-0001 Cover hood 51004015-0001 Stud bolt 51400305-0001 Foundation 51500606 On-Off switch 51500807-0001 Potentiometer complete 51500608 Turn switch 51500624-0001 Emergency off switch complete 51500102-0002 Engine 51500619...
Drawings and legends 15.4 Change gear quadrant for D2000/D2400/D3000...
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Drawings and legends 15.4 Change gear quadrant for D2000/D2400/D3000 Part No. Items Order No. Description 51004020-0010 Washer 51004025-0008 Sleeve 51004633-0004 Wheel bolts alternately short 51006831-0013 Change gear quadrant 51004020-0009 Washer 51004633-0003 Wheel bolts alternately long 51006580-0004 Toothed belt wheel Z48...
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Drawings and legends 15.5 Transmission and lead screw drive for D2000/2400/D3000...
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Drawings and legends 15.5 Transmission and lead screw drive for D2000/2400/D3000 Part No. Items Order No. Description 16173490176530 Washer 51006831-0015 Spindle guide 51004018-0001 Adjusting ring transmission 51004015-0007 Spindle 51400220-0001 Snip holder 51006580-0003 Belt washer 51006831-0014 Clamping piece 51004020-0008 Spacer 51006580-0002 Belt washer...
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Drawings and legends 15.5 Transmission and lead screw drive for D2000/D2400/D3000...
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Drawings and legends 15.5 Transmission and lead screw drive for D2000/D2400/D3000 Part No. Items Order No. Description for D2400 51004012-0005 Eccentric shaft 51004030-0006 Adjusting ring 51004025-0034 Feed shaft 51004045-0006 Coupling element 51003435-0002 Coupling disk 51507018 Tensioning nut 51502117 Ball bearing 51502021...
Drawings and legends 15.6 Lead screw drive for D3000...
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Drawings and legends 15.6 Lead screw drive for D3000 Part No. Items Order No. Description 51500110 DC motor with transmission 51502326 Gear belt 51004040-0012 Toothed belt wheel 51400304-0001 Motor holder 16191200006016 Screw 51400303-0001 Mounting bracket 51004025-0036 Setting nut 51004025-0040 Washer 51004025-0008 Sleeve 51502101 Needle roller thrust bearing 51004035-0014...
Circuit diagram 16.3 Key for circuit diagram Color-code by IEC 60757 Black Pink Brown Blue Violet Green White Gray Yellow Orange Green/Yellow Main spindle motor Feed motor Power plug Motor plug Clamping bar Motor control board Feed board 220 kΩ (ohm) potentiometers spindle speed 10 kΩ (ohm) potentiometers spindle speed Emergency switch-off Main switch End switch chuck -cover Turn switch spindle right/left Feed direction Speedometer Thermistor...
The diameter of the through holes in the surface must be at least 9 mm. The supplied fixture screws are designed for the installation on a WABECO machine base cabinet. If the chip tray with splash guard is attached to another, suitable surface, screws suitable for the thickness of the surface must be used. Ø10 (4x) D2000 Ø10 (4x) D2400 and D3000...
Chip tray with splash guard (optional) 17.2 Mounting the chip tray with splash guard on the tool cabinet (optional) ■ The chip tray with splash guard (2) is positioned, as shown, on the machine base cabinet (1). The two spacer feet’s (3) are not relevant in this stage. ■ The screws and washers required for assembly are included in the scope of delivery.
18.1 Setting up the coolant unit When mounting the coolant unit to a WABECO machine base cabinet, the appropriate bores are already present. The machine base cabinet ensures a safe base for the lathe or coolant unit. If the coolant unit 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 unit (optional) 18.2 Mounting of the coolant unit to the machine base cabinet (optional) ■ The coolant unit (2) is positioned, as shown, on the machine base cabinet (1). The two spacer feet’s (3) are not relevant in this stage. ■ The screws and washers required for assembly are included in the scope of delivery. To screw the coolant unit to the machine base cabinet proceed as follows: 1.
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Coolant unit (optional) 18.2 Mounting of the coolant unit to the machine base cabinet (optional) To screw the coolant unit to the machine base cabinet proceed as follows: 1. Position both spacer feet’s (3) as shown upon the coolant unit (2) and align along the fixing holes of the coolant unit. 2. Place the lathe carefully onto the spacer feet’s and align the fixing holes. 3. Remove both shelf inserts out of the coolant unit. 4.
Coolant unit (optional) 18.4 Filling the coolant unit 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 from the supplier or manufacturer).
Coolant unit (optional) 18.6 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. Attention should be paid to ensure that the nozzle does not come into contact with the cutting tool. 18.7 Controlling the flow of coolant using the coolant shut-off valve Coolant shut-off valve in the „open“...
Coolant system (optional) 18.8 Drawing and legend Part No. Items Order No. Description 51401163-0001 Coolant unit (tank and two shelf inserts) 51500119 Coolant pump 51504320 Screw-fitted hose bush 51504218 PVC fabric hose 51504318 Screw-fitted hose bush 51400400-0001 Bracket 51504349 Collar 51502507 Coolant hose with shut-off valve 16191200006016 Screw 16112500006001 Washer 16191200004010 Screw 16112500004000...
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Coolant unit (optional) 18.8 Drawing and legend Screws for securing the lathe to the coolant unit and for securing the segmented coolant hose Part No. Items Order No. Description 51002115-0001 Spacer feet 16193300010025 Screw 16112500010000 Washer 16191200008040 Screw 16112500008001 Washer...
Fixed stay (optional) Stays 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 workpiece is precisely flush with the rotating axis of the machine. At eth support position, the turning parts must be accurately rounded. 19.1 Operating the fixed stay 1.
Live stay (optional) Stays 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 workpiece is precisely flush with the rotating axis of the machine. At eth support position, the turning parts must be accurately rounded. 20.1 Operating the live stay 1.
Live stay (optional) 20.2 Drawing and legend Part No. Items Order No. Description 51006831-0032 Basic body 16147100008000 Securing ring 51502117 Ball bearing 51401533-0001 Slider with axis 16112500008001 Washer 16193300008020 Screw 16155700008000 16191200008025 Screw...
Clamping angle with milling attachment (optional) For drilling and milling work ■ For creating even surfaces and grooves. ■ The feed and return motions are carried out by the workpiece. ■ Put the used clamping screws into the T-groove of the clamping plate. It is necessary that the corresponding clamping screw fit to the clamping plate.
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Clamping angle with milling attachment (optional) 21.1 Mounting of the clamping angle with milling attachment 8. Tighten the nut (12) through the use of an wrench in size 16mm. 9. Position the milling attachment (6) upon the pivot of the longitudinal slide. 10. Position both push pieces (8) in the lateral bored holes of the milling attachments. 11. Align the milling attachment and arrest the same through tightening both screws (3) using an Allen key of size 4. 12. Plug the included dust cover (4) into the center hole of the cross slide. The positions 1, 2, 3, 5, 11 and 12 are not included in the scope of delivery. They belong to the lathe.
Clamping angle with milling attachment (optional) 21.2. Control elements 1. Crank for adjustment of the milling attachment in the y axis 2. Scale ring for reading off the travel distance of the y axis 3. Lubrication nipple for greasing the spindle bearing 4. Counter nut for securing the threaded pins (5) 5. Threaded pins for setting the guide play 6.
Clamping angle with milling attachment (optional) 21.4 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.
Collet chuck (optional) Only use workpieces that correspond to the nominal diameter of the collet. 22.1 Mounting the collect chuck 1. Remove the lathe chuck from the main spindle. To do this, undo the 3 fixing screws using a wrench. 2. Remove the lathe chuck from the centring flange of the main spindle. 3. Secure the collet chuck in the same way as the lathe chuck. 4. Remove the cap nut (1) from the collet chuck (2). 5. Insert the required collect into the cap nut (see installing and removing collets) and screw back onto the collet chuck.
A-A ( 1 : 1 ) Collet chuck (optional) 22.3 Installation and removal of collets Installation 1. Place the collet on a flat surface. 2. Place the tensioning nut on the collet. 3. Press the tensioning nut down against the collet until it „clicks“. 4. The collet can now move freely in the central take-up shoulder and does not fall out when the collet is turned upside down. A-A ( 1 : 1 ) 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.
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