AMMCO 6000 Heavy Duty Drum User Manual
1601 J. P. Hennessy Drive, LaVergne, TN USA 37086-3565 615/641-7533 800/688-6359 Manual Part No.: 921657 18
HENNESSY INDUSTRIES INC. Manufacturer of AMMCO
®
, COATS®and BADA®Automotive Service Equipment and Tools. Revision: 06/01
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.
6000, 6002
Heavy Duty
Drum/Disc Lathe
®
ii • AMMCO 6000, 6002 Brake Lathes
Brake Lathes
AMMCO 6000, 6002 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
Installation
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Preferred Lifting Method . . . . . . . . . . . . . . . . . . .1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Electrical Wiring Requirements . . . . . . . . . . . . . .2
Electrical Hook-Up . . . . . . . . . . . . . . . . . . . . . . . .2
Terminal Block Diagram . . . . . . . . . . . . . . . . . . . .2
Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Lathe Operation
Operating Specifications . . . . . . . . . . . . . . . . . . .3
Work Space Requirements . . . . . . . . . . . . . . . . .3
Control Panel Functions . . . . . . . . . . . . . . . . . . . .4
Electrical Overload Safety Breaker . . . . . . . . . . . .4
Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . .4
Saddle and Cross Slide Locks . . . . . . . . . . . . . . .5
Feed Gearbox Engagement Levers . . . . . . . . . . .5
Handwheel Depth-Of-Cut Dials . . . . . . . . . . . . . .5
Gearbox Function & Handwheel Operation . . . . .6
Typical Drum Mounting . . . . . . . . . . . . . . . . . . . .7
Brake Drum Reconditioning . . . . . . . . . . . . .8 - 10
Typical Rotor Mounting . . . . . . . . . . . . . . . . . . .11
Brake Rotor Reconditioning . . . . . . . . . . . . .12 - 13
Maintenance and Service
Oiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Adjusting Gibs . . . . . . . . . . . . . . . . . . . . . . . . . .14
Care of Arbors and Adapters . . . . . . . . . . . . . . .15
Drive Belt Replacement . . . . . . . . . . . . . . . . . . .16
Main Power Switch Bulb Replacement . . . . . . .16
Drive Motor Brush Replacement . . . . . . . . . . . .16
Feed Motor Brush Replacement . . . . . . . . . . . .17
Electrical Cords . . . . . . . . . . . . . . . . . . . . . . . . .17
Overload Safety Fuse Replacement . . . . . . . . . .17
Contents
iv • AMMCO 6000, 6002 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. Theref ore, 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 6000, 6002 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 6000, 6002 Brake Lathes
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 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 t aken 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 necessar y, 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
completely away from the work area.
11. Make the workshop kid-proof. Use padlocks and
master switches, and remove starter keys.
12. Don’ t f orce 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 eyeglasses 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. A lways 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.
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
Installation
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 eff ect that y ou hav e 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 responsibilit y 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.
Preferred Lifting Method
Lift the lathe by all four bed ways only. DO NOT lift
under the saddles, cross slides, boring bars, or spindle. Be sure the gearbox control wires and external
travel controls will not be damaged when lifting the
lathe.
Be sure the lifting slings are arranged so they will not crush or
exert pressure against any limit switch control parts, lock levers,
control wires, etc.
Both slings should be hung together in a hook or a loop of c hain
when lifting the lathe.
Installation
Bolt the lathe to the floor using the anchor bolts provided. Be
sure the lathe is resting solidly on its three feet. Shim with washers if necessary to eliminate rocking. After the lathe is bolted
down run the outer corner screws of the front support down
until they contact the floor and tighten the jam nuts. These
screws are not to be used for leveling. BEFORE RUNNING THE
LATHE, REFER TO THE OILING AND GREASING INSTRUCTIONS. Allow sufficient work space around the lathe as illustrated in the WORK SPACE REQUIREMENTS.
Brake Lathes
AMMCO 6000, 6002 Brake Lathes • 1
CAUTION
Electrical Wir ing Requirements
The lathe is factory wired to a disconnect box whic h should be
grounded to the power supply box in accordance with local code
requirements to protect the operator from shock.
The lathe is grounded to the disconnect box through the flexible conduit. The flexible conduit should not be removed or
eliminated.
This box is to be mounted to the wall behind the machine.
A qualified electrician should complete the hook-up to line
power of 220 VAC, 50~60 Hz, Single Phase, 20 amps.
Before operating the lathe be sure the drive motors are connected at the terminal plate as shown in Fig. 1.
Electrical Hook-Up
Connect one incoming power line to the screw terminal at the
top of the fuse above the red lathe wire and the other power
line to the screw terminal at the top of the fuse above the black
lathe wire, Fig. 2. Check the voltage between the red and black
power lines with a voltmeter. The meter will show 220 volts
when properly wired.
Note:The incoming power lines must be supplied by the consumer and must be in accordance with local code requirements.
The incoming power lines may be colors other than red and
black.
Terminal Block Diagram
Work Lamp
The work lamp is designed for a maximum bulb wattage of 75
wat ts. Exceeding 75 w atts will damage the lamp shade. Be sure
to use 220 volt bulbs only.
Brake Lathes
2 • AMMCO 6000, 6002 Brake Lathes
Figure 1 - Drive Motor Electric Cables Connected To
Terminal Plate
Figure 2 - Disconnect Box Hook-up (Black To Black,
Red T o Red)
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