AMMCO 3860 Drum & Disc Brake Lathe User Manual
1601 J. P. Hennessy Drive, LaVergne, TN USA 37086-3565 615/641-7533 800/688-6359 Manual Part No.: 929250 09
HENNESSY INDUSTRIES INC. Manufacturer of AMMCO
®
, COATS®and BADA®Automotive Service Equipment and Tools. Revision: 05/01
3850, 3860
Drum & Disc
Brake Lathes
®
Installation Instructions
Operating Instructions
Safety Instructions
Maintenance Instructions
READ these instructions before placing unit in
service. KEEP these and other materials delivered
with the unit in a binder near the machine for
ease of reference by supervisors and operators.
ii • AMMCO 3850, 3860 Brake Lathes
Brake Lathes
AMMCO 3850, 3860 Brake Lathes • iii
Table of Contents
Safety Notices and Decals . . . . . . . . . . . . .iv
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
Cautions and Dangers . . . . . . . . . . . . . . . . . . . .iv
Owner’s Responsibility . . . . . . . . . . . . . . . .v
Definitions of Hazard Levels . . . . . . . . . . . .v
Important Safety Instructions . . . . . . . . . .vi
Before You Begin
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Electrical Requirements . . . . . . . . . . . . . . . . . . . .1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Preparation for Use . . . . . . . . . . . . . . . . . . . . . . .2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Principle Operating Parts . . . . . . . . . . . . . . . . . . .3
Operating Instructions
Negative and Positive Rake Tooling . . . . . . . . . . .3
Starting the Lathe . . . . . . . . . . . . . . . . . . . . . . . .4
Selecting Feed Drive Direction - Rotor or Drum . .4
Reading the Drum Depth-of-Cut Micrometer Dial . .5
Arbor Installation . . . . . . . . . . . . . . . . . . . . . . . . .5
Mounting Drums . . . . . . . . . . . . . . . . . . . . . . . . .6
Reconditioning Brake Drums . . . . . . . . . . . . . . . .6
Mounting Brake Rotors . . . . . . . . . . . . . . . . . . .10
Reconditioning Brake Rotors . . . . . . . . . . . . . . .11
Maintenance and Service . . . . . . . . . . . . .14
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Arbor and Adapter Care . . . . . . . . . . . . . . . . . . .15
Gib Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .16
3860 Drum Tool Bar Adjustment . . . . . . . . . . . .17
Contents
iv • AMMCO 3850, 3860 Brake Lathes
Safety
Safety Notices and
Decals
For your safety, and the safety of others, read and
understand all of the safety notices and decals included here and on the unit.
Read entire manual
before installing,
operating, or servicing this equipment.
Proper maintenance
and inspection is
necessary for safe
operation.
Do not operate a
damaged lathe.
Warning
This equipment incorporates parts such as snap
switches and power receptacles which tend to produce arcs or sparks. Therefore, when located in a service facility, the unit should be in a room or enclosure
provided for the purpose, or should be at least 18” or
more above floor to minimize the risk of igniting fuel
vapors.
Cautions and Dangers
1. Eye and face protection requirements:
“Protective eye and face equipment is required
to be used where there is a reasonable
probability of injury that can be prevented by use
of such equipment.” OSHA 1910.133 (a).
Protective goggles, safety glasses, or a face
shield must be provided by the purchaser/user
and worn by the operator of the equipment.
Make sure all eye and face safety precautions are
followed by the operator(s). Keep bystanders out
of the area.
2. Do not remove any safety equipment, belt
guards, or shortcut controls or operations.
3. Make sure drums and rotors are properly and
squarely mounted before starting lathe, and that
all parts are secure.
4. Do not wear loose clothing, jewelry, or gloves
when operating or working around a lathe.
5. Do not overload the lathe. Read and understand
the lathe specifications. Overloading is poor
machine tool practice, shortens the life of the
lathe, and could cause a failure resulting in
personal injury.
Failure to follow danger, warning, and caution
instructions may lead to serious personal injury or
death to operator or bystander or damage to property. Do not operate this machine until you read
and understand all the dangers, warnings and cautions in this manual. For additional copies of either,
or further information, contact:
Hennessy Industries, Inc.
1601 J.P. Hennessy Drive
LaVergne, TN 37086-3565
(615) 641-7533 or (800) 688-6359
www.Hennessy-Ind.com
WARNING
AMMCO 3850, 3860 Brake Lathes • v
Owner’s Responsibility
To maintain machine and user safety, the responsibility of the owner is to read and follow these instructions:
• Follow all installation instructions.
• Make sure installation conforms to all applicable
Local, State, and Federal Codes, Rules, and
Regulations; such as State and Federal OSHA
Regulations and Electrical Codes.
• Carefully check the unit for correct initial function.
• Read and follow the safety instructions. Keep
them readily available for machine operators.
• Make certain all operators are properly trained,
know how to safely and correctly operate the
unit, and are properly supervised.
• Allow unit operation only with all parts in place
and operating safely.
• Carefully inspect the unit on a regular basis and
perform all maintenance as required.
• Service and maintain the unit only with
authorized or approved replacement parts.
• Keep all instructions permanently with the unit
and all decals/labels/notices on the unit clean and
visible.
• Do not override safety features.
Definitions of Hazard
Levels
Identify the hazard levels used in this manual with
the following definitions and signal words:
DANGER
Watch for this symbol:
It Means: Immediate hazards, which will result in
severe personal injury or death.
WARNING
Watch for this symbol:
It Means: Hazards or unsafe practices, which could
result in severe personal injury or death.
CAUTION
Watch for this symbol:
It Means: Hazards or unsafe practices, which may
result in minor personal injury or product or property
damage.
Watch for this symbol! It means BE ALERT! Your
safety, or the safety of others, is involved!
Safety
1. Read and follow instructions.
2. Always wear eye protection, avoid loose
clothing and jewelry.
3. Keep all guards, shields, and covers in place and
in working order.
4. Keep bystanders out of work area.
5. Unplug unit from power source before servicing
or adjusting.
6. Maintain unit properly, keep work surfaces and
work area clean.
CAUTION
Prevent accidents and injury, read and follow instructions.
DANGER
WARNING
CAUTION
vi • AMMCO 3850, 3860 Brake Lathes
READ ALL INSTRUCTIONS
When using your garage equipment, basic safety precau-
tions should always be followed, including the following:
1. Keep guards in place and in working order.
2. Remove adjusting keys and wrenches from the tool
before turning it on. Make this a habit.
3. Keep work area clean and well lighted. Cluttered areas
and benches invite accidents.
4.To reduce the risk of fire, do not operate equipment in the
vicinity of open containers of flammable liquids (gasoline).
5. Adequate ventilation should be provided when working
on operating internal combustion engines.
6. Care must be taken as burns can occur from touching
hot parts.
7. Do not operate equipment with a damaged cord or if the
equipment has been dropped or damaged—until it has been
examined by a qualified serviceman.
8. If an extension cord is necessary, a cord with a current
rating equal to or more than that of the equipment should be
used. Cords rated for less current than the equipment may
overheat. Care should be taken to arrange the cord so that it
will not be tripped over or pulled.
9. To reduce the risk of electric shock, do not use on wet
surfaces or expose to rain.
10. Keep children away. All bystanders should be kept com-
pletely away from the work area.
11. Make the workshop kid-proof. Use padlocks and mas-
ter switches, and remove starter keys.
12. Don’t force a tool. It will do the job better and safer at
the rate for which it was designed.
13. Use the right tool. Don’t force a tool or an attachment
to do a job for which it was not designed.
14. Dress properly. Keep hair, loose clothing, neckties,
shop rags, jewelry, fingers, and all parts of body away from
moving parts. Non-slip footwear is recommended.
15. ALWAYS WEAR SAFETY GLASSES. Everyday eye-
glasses only have impact resistant lenses, they are NOT
safety glasses. Safety glasses, goggles, or a face shield will
help protect the operator from injury. Use a face shield and
dust mask during dusty operations.
16. Secure the work properly to the unit for setup and tool
bit positioning. Do not attempt to hold a drum or rotor steady
on the arbor with your hands. Both hands must be free to
operate unit.
17. Don’t overreach. Keep proper footing and balance at all
times when lathe is in operation or when working around the
unit.
18. Maintain tools with care. Keep tools sharp and clean for
best and safest performance. Follow instructions for lubricating and changing accessories.
19. Remove power from the unit and disconnect tools
before servicing and when changing accessories such as
blades, bits, cutters, etc. Follow lock-out and tag-out procedures as required.
20. Avoid unintentional starting. Make sure the switch is in
the OFF (O) position before plugging the machine in or performing any maintenance or service work.
21. Use of improper accessories may cause risk of injury to
operator or bystanders. Use only as described in this manual.
Use only manufacturer’s recommended attachments.
22. Never stand or lean on a lathe. Serious injury could
occur if the lathe is tipped or if the cutting tool is unintentionally contacted.
23. Check damaged parts carefully. Before further use of
the lathe, a guard or other part that is damaged should be
carefully checked. Immediately replace all damaged, missing,
or non-functional parts. Check for alignment of moving parts,
binding of moving parts, breakage of parts, mounting, and any
other conditions that may affect operation. Guards and other
parts that are damaged should be properly repaired or
replaced before lathe is used again.
24. Always feed the work into a blade or cutter and against
the direction of rotation. Cutters and tool bits are designed to
cut from the inside of a drum or rotor to the outer edge. Do
not attempt to cut from the outside edge in to the center.
25. Never leave tools running unattended. Turn the power
off. Don’t leave the tool until it comes to a complete stop.
26. Never use compressed air to blow the tool clean. Chips
and dust may be driven between machined parts and into
bearings, causing undue wear. They may also contact persons
in the area causing personal injury.
27. Operate the lathe in the proper environment. The lathe
incorporates parts such as snap switches and power receptacles which tend to produce arcs or sparks. Therefore, when
located in a garage,the unit should be in a room or enclosure
provided for the purpose, or should be at least 18” or more
above the floor to minimize the risk of igniting fuel vapors.
Before operating the lathe, review the warning information on the lathe and the cautions, warnings and dangers in this manual. Also review the following general safety instructions. Failure to follow safety instructions could result in personal injury to
operator or bystanders and damage to the lathe or personal property.
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
Brake Lathes
AMMCO 3850, 3860 Brake Lathes • 1
Before You Begin
Receiving
The shipment should be thoroughly inspected as soon as it is
received. The signed bill of lading is acknowledgement by the
carrier of receipt in good condition of shipment covered by our
invoice.
If any of the goods called for on this bill of lading are shorted
or damaged, do not accept them until the carrier makes a notation on the freight bill of the shorted or damaged goods. Do this
for your own protection.
NOTIFY THE CARRIER AT ONCE if any hidden loss or damage
is discovered after receipt and request the carrier to make an
inspection. If the carrier will not do so, prepare a signed statement to the effect that you have notified the carrier (on a specific date) and that the carrier has failed to comply with your
request.
IT IS DIFFICULT TO COLLECT FOR LOSS OR DAMAGE AFTER
YOU HAVE GIVEN THE CARRIER A CLEAR RECEIPT.
File your claim with the carrier promptly. Support your claim
with copies of the bill of lading, freight bill, invoice, and photographs, if available.
Although AMMCO's responsibility ceases upon delivery of the
shipment to the carrier, we will gladly assist in tracing lost shipments. Our willingness to assist in every possible manner does
not make AMMCO responsible for collection of claims or
replacement of lost or damaged materials. Shipping damage
claims will not be handled under warranty.
Electrical Requirements
The lathe must be properly grounded to protect the operator
from shock. The lathe is equipped with an approved 3-conductor
cord and a 3-prong grounding type plug to fit the proper grounding-type receptacle. Should an extension cord be required, use
3-conductor cords with 3-prong grounding plug and 3-prong
grounding receptacle properly rated to handle this electrical
power tool only. Do not modify a cord or plug to match a receptacle; have a qualified electrician install an appropriate outlet to
match the lathe requirements. Repair or replace any worn or
damaged power cords immediately.
The lathe requires a single-phase power source of 115 VAC
(±10%), 60 Hz, fused at 15 A for proper operation.
Figure 1 - Power Cord Plug and Receptacle
Installation
1. Assemble bench according to the instructions provided.
Tighten all fasteners securely.
2. After assembly, the bench should be leveled and bolted
down with 3/8 or 7/16 inch bolts or lag screws.
3. Unbolt the lathe from the shipping pallet. Lift the lathe onto
the bench using the eye bolt located on top of the lathe. Do not
lift the lathe by the motor, pulley cover, crossfeed endcap, or
leadscrew protective tube on the rear of the unit.
4. Bolt the lathe to the bench with the hardware provided.
Tighten fasteners securely.
5. Remove any packing materials and protective wrapping
from the lathe and components.
6. Make sure lathe is turned off (switch in "O" position). Plug
lathe into a properly installed and grounded outlet that matches
the lathe plug.
7. Clear the area and turn lathe on. Check for proper operation
(motor and spindle rotation).
Preparation for Use
1. Inspect all adapters and accessories for burrs, nicks, or
other damage.
2. Clean accessories with a vaporizing solvent.
3. Apply a light film of oil to all adapters to protect their
machined surfaces from rust. Refer to the maintenance section
for more information.
Specifications
Overall Lathe Height . . . . . . . . . . . . . . . . . . . . . . . . . . .16.5 in
Spindle to Floor (on AMMCO bench) . . . . . . . . . . . .39.625 in
Spindle Speed (full load) . . . . . . . . . . . . . . . . . . . . . .175 RPM
Rotor Slide Feed Rate . . . . . . . . . . . . . . . . . . . . .0.0013 in/rev.
Drum Slide Feed Rate . . . . . . . . . . . . . . . . . . . .0.0026 in/rev.
Micrometer Graduations . . . . . . . . . . . . . . . . . . . . . . .0.002 in
Max. Brake Rotor Diameter . . . . . . . . . . . . . . . . . . . . .21.5 in
Max. Brake Rotor Thickness . . . . . . . . . . . . . . . . . . . . .1.75 in
Min. Brake Drum Diameter . . . . . . . . . . . . . . . . . . . . . .6.0 in
Max. Brake Drum Diameter . . . . . . . . . . . . . . . . . . . . .30.0 in
Max.Brake Drum Depth . . . . . . . . . . . . . . . . . . . . . . . . .6.0 in
Max. Load, 1 inch arbor . . . . . . . . . . . . . . . . . . . . . . . .100 lbs
Max. Load, 1-7/8 inch arbor . . . . . . . . . . . . . . . . . . . . .200 lbs
Spindle Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 HP
Electrical Requirements . . . . . . . . . . . . . . . . . .115 VAC, 60 Hz
Single-Phase, Fused at 15A
Lathe Weight (lathe only) . . . . . . . . . . . . . . . . . . . . . .452 lbs
Floor Space (on opt. bench) . . . . . . . . . . .33.5 in W x 31 in D
Brake Lathes
2 • AMMCO 3850, 3860 Brake Lathes
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