4000E
Drum & Disc Brake Lathe
®
* Brake lathe shown on bench with sign, toolboard and accessories.
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.
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 |
IMPORTANT SAFETY INSTRUCTIONS
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.
READ ALL INSTRUCTIONS
When using your garage equipment, basic safety precautions 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 master 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 manufacturer’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, grounding 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.
SAVE THESE INSTRUCTIONS
ii • AMMCO Drum & Disc Brake Lathes
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
AMMCO Drum & Disc Brake Lathes • 1
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:
DANGER
It Means: Immediate hazards, which will result in severe personal injury or death.
WARNING Watch for this symbol:
WARNING
It Means: Hazards or unsafe practices, which could result in severe personal injury or death.
CAUTION Watch for this symbol:
CAUTION
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!
2 • AMMCO Drum & Disc Brake Lathes
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
CAUTION 
Prevent accidents and injury,read and follow instructions.
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.
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.
WARNING
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
AMMCO Drum & Disc Brake Lathes • 3
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.
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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 displayed.
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
4 • AMMCO Drum & Disc Brake Lathes
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