AMMCO 4000E Drum and Disc Brake lathe User Manual
1601 J. P. Hennessy Drive, LaVergne, TN USA 37086-3565 615/641-7533 800/688-6359 Manual Part No.: 95000103 01
HENNESSY INDUSTRIES INC. Manufacturer of AMMCO
®
, COATS®and BADA®Automotive Service Equipment and Tools. Revision: 04/08
4000E
Drum & Disc
Brake Lathe
®
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.
* Brake lathe shown on
bench with sign, toolboard
and accessories.
Installation Instructions
Operating Instructions
Safety Instructions
Maintenance Instructions
ii • AMMCO Drum & Disc 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. Cluttered areas and benches
invite accidents.
4. Avoid dangerous operating environments. Do not use
power tools in areas where explosive vapors are present or
in damp of wet locations. Do not expose them to rain. Keep
the work area clean and well lighted.
5. Keep children away. All bystanders should be kept
completely away from the work area.
6. Make the workshop kid-proof. Use padlocks and mas-
ter switches, and remove starter keys.
7. Don’t force a tool. It will do the job better and safer at
the rate for which it was designed.
8. Use the right tool. Don’t force a tool or an attachment
to do a job for which it was not designed.
9. Dress properly. Keep loose clothing, gloves, neckties,
shop rags or jewelry may get caught in moving parts. Nonslip footwear is recommended. Wear protective hair covering to contain long hair.
10. Wear eye protection. Safety glasses, goggles, or a
face shield will help protect the operator from injury. Use a
face shield and dust mask during dusty operations.
11. 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.
12. Don’t overreach. Keep proper footing and balance at
all times when lathe is in operation or when working around
the unit.
13. Maintain tools with care. Keep tools sharp and clean
for best and safest performance. Follow instructions for
lubricating and changing accessories.
14. 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.
15. 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.
16. Use recommended accessories. Consult the manu-
facturer’s catalogs for recommended accessories. Use of
improper accessories may cause risk of injury to operator or
bystanders.
17. Never stand or lean on a lathe. Serious injury could
occur if the lathe is tipped or if the cutting tool is unintentionally contacted.
18. 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.
19. 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.
20. Never leave tools running unattended. Turn the
power off. Don’t leave the tool until it comes to a complete
stop.
21. 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.
22. 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.
23. In the event of a malfunction or breakdown, ground-
ing provides a path of least resistance for electric shock, this
tool is equipped with an electric cord having an equipmentgrounding conductor and a grounding plug, the plug must
be plugged into a matching outlet that is properly installed
and grounded in accordance with all local codes and ordinances.
24. Improper connection of the equipment-grounding
conductor can result in a risk of electric shock. The conductor with insulation having an outer surface that is green with
or without yellow stripes is the equipment-grounding conductor. If repair or replacement of the electric cord or plug
is necessary, do not connect the equipment-grounding conductor to a live terminal.
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
AMMCO Drum & Disc Brake Lathes • 1
Table of Contents
Important Safety Instructions . . . . . . . . . . . .ii
Owner’s Responsibility . . . . . . . . . . . . . . . . . . . . .2
Definitions of Hazard Levels . . . . . . . . . . . . . . . . .2
Safety Notices and Decals . . . . . . . . . . . . . . . . . . .3
Cautions and Dangers . . . . . . . . . . . . . . . . . . . . . .3
Principle Operating Parts . . . . . . . . . . . . . . . .4
Know Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Basic Operation . . . . . . . . . . . . . . . . . . . . . . .6
Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Spindle Jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Spindle Feed Rate . . . . . . . . . . . . . . . . . . . . . . . . .6
Spindle Speed and Adjustment . . . . . . . . . . . . . . .6
Speed and Feed Reference Chart . . . . . . . . . . . . .6
Cross Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Cross Feed Handwheel & Feed Lever . . . . . . . . . .7
Twin Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Boring Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Reconditioning Disc Brake Rotors . . . . . . . .8
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Model 6950 Twin Cutter . . . . . . . . . . . . . . . . . . . .8
Rotor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Double Chuck Adapter . . . . . . . . . . . . . . . . . . . . .10
Set Up and Reconditioning Rotors . . . . . . . . . . . .10
Reconditioning Brake Drums . . . . . . . . . . .13
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Mounting Drum . . . . . . . . . . . . . . . . . . . . . . . . . .13
Maintenance and Service . . . . . . . . . . . . . .16
Oiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Care of Arbors and Adapters . . . . . . . . . . . . . . . .16
Installation Instructions . . . . . . . . . . . . . . . .17
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Electrical Requirements . . . . . . . . . . . . . . . . . . . .17
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Connect to Power . . . . . . . . . . . . . . . . . . . . . . . .17
Operating Specifications . . . . . . . . . . . . . . . . . . .17
2 • AMMCO Drum & Disc Brake Lathes
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 and make sure
installation conforms to all applicable Local, 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 unit clean and visible.
• If ownership of the unit is transferred, provide
new owner all information, manuals, and provide
AMMCO new ownership information.
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!
CAUTION
WARNING
DANGER
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
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.ammcoats.com
WARNING
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.
AMMCO Drum & Disc Brake Lathes • 3
4 • AMMCO Drum & Disc Brake Lathes
Principal Operating Parts
Know Your Unit
Compare this illustration with the unit before placing it into service. Maximum performance and safety will be
obtained only when all persons using the unit are fully trained in its parts and operation. Each user should learn
the function and location, of all controls.
Prevent accidents and injuries by ensuring the unit is properly installed, operated and maintained.
Control Console
Rotor Rough Cut – press to activate.
Rotor Finish Cut – press to activate.
Rotor Start/Stop – press to start or stop feed.
- (Minus) – press to decrease feed rate value dis-
played.
Feed Rate Display – indicates the value selected for
rough and finish feed rates.
+ (Plus) – – press to increase the feed rate value
displayed.
Spindle Jog – moves the spindle in the direction
indicated. Only active in drum mode.
Drum Rough Cut – press to activate.
Drum Finish Cut – press to activate.
Drum Start/Stop – press to start or stop feed.
4100E Brake Lathe
Control Console
Grease Fitting
Cross Feed Gearbox
Oil Dipstick
Drive Motor Pulley Guard
Drum Feed Gearbox Assembly
Draw Bar
Twin Cutter
Work Light
Spindle Arbor
Spindle Lock Knob
Cross Feed Handwheel
Feed Lever
Cross Feed Lock
Cross Feed Lock Knob
Spindle Speed Adjusting Lever
Power Cord
ON/OFF Switch
Boring Bar and Boring Clamp
8 8
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